kashyap main project 1

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STUDY AND ANALYSIS OF LOW STRENGTH

CONCRETE USING CERAMIC AGGREGATE AND FLY

ASH

A PROJECT REPORT

Submitted by

1. KASHYAP.V 080104202023

2. PRASANTH GEORGE 080104202031

3. TIJO.K.THOMAS 080104202048

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

CIVIL ENGINEERING

SAPTHAGIRI COLLEGE OF ENGINEERING, DHARMAPURI

ANNA UNIVERSITY OF TECHNOLOGY, COIMBATORE

641047


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STUDY AND ANALYSIS OF LOW STRENGTH

CONCRETE USING CERAMIC AGGREGATE AND FLY

ASH

A PROJECT REPORT

Submitted by

1. KASHYAP.V 080104202023

2. PRASANTH GEORGE 080104202031

3. TIJO.K.THOMAS 080104202048

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

In

CIVIL ENGINEERINGSAPTHAGIRI COLLEGE OF ENGINEERING, DHARMAPURI

ANNA UNIVERSITY OF TECHNOLOGY, COIMBATORE

641047


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ANNA UNIVERSITY OF TECHNOLOGY

COIMBATORE - 641047

BONAFIDE CERTIFICATE

Certified that this project report STUDY AND ANALYSIS OF LOW

STRENGTH CONCRETE USING CERAMIC AGGREGATE AND FLY ASH

is the bonafide work of KASHYAP.V (080104202023) who carried out the

project work under my supervision.

SIGNATURE SIGNATURE

SUPERVISOR HEAD OF THE DEPARTMENT

Mr.P.JAWAHAR.M.tech Mr.A.ARIVALAGAN.M.Tech.MBA.

DEPT OF CIVIL ENGINEERING DEPT OF CIVIL ENGINEERING

SAPTHAGIRI COLLEGE OF ENGG. SAPTHAGIRI COLLEGE OF ENGG.

DHARMAPURI DHARMAPURI

Submitted to the viva voice examination ------------------------- --------------------------------

INTERNAL EXAMINER EXTERNAL EXAMINER


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COIMBATORE - 641047




is the bonafide work of PRASANTH GEORGE (080104202031) who carried

out the project work under my supervision.

SIGNATURE SIGNATURE


Mr.P.JAWAHAR.M.Tech Mr.A.ARIVALAGAN.M.Tech.MBA.







5/52


COIMBATORE - 641047




is the bonafide work of TIJO.K.THOMAS (080104202048) who carried out the

project work under my supervision.

SIGNATURE SIGNATURE









6/52


COIMBATORE - 641047




is the bonafide work of KASHYAP.V (080104202023) , PRASANTH

GEORGE (080104202031) , TIJO.K.THOMAS (080104202048) who carried

out the project work under my supervision.

SIGNATURE SIGNATURE









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CONTENTS

S.L.NO TITLE PAGE NO

1. ACKNOWLEDGEMENT

2. ABSTRACT

3. INDRODUCTION

4. GENERAL ABOUT CERAMIC AGGREGATE

5. GENERAL ABOUT FLY ASH

6. RAW MATERIALS AND MIXED RATIO

7. MIXED DESIGN

8. MANUFACTURING PROCESS OF CERAMIC AND FLY

ASH MIXED CONCRETE

9. GENERAL ABOUT CUBE TEST AND CYLINDER TEST

10. TEST MADE ON SAMPLE

11. CONCLUSION

12. REFFERENCES

13. PICTORIAL REPRESENTATION


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ACKNOWLEDGEMENT

We should like to express our sincere gratitude to our grateful chairman

Thiru. M.G. SEKHAR, B.A., B.L., for providing large facilities for progress.

We take great pleasure in expressing our sincere thanks to our principle Prof.K.N.

Bhanuprakash, M.E, Ph.D.for his valuable ideas regarding our project.

We express our sincere thanks to Mr.A.ARIVALAGAN.M.Tech, MBA. Head of

the Department, who spend his valuable time for us in guiding throughout the project work,.

We would like to express profusely our deep sense of gratitude to our Supervisor

MR.P.JAWAHAR., M.E., for his kind advice, encouragement and for having granted permissionto work this project.

We wish to acknowledgement our thanks to all the staff members ofDepartment of

CIVIL ENGINEERING, our friends and other well wishers who helped us to complete this

project work successfully.


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ABSTRACT

We have taken the topic about LOW STRENGTH CONCRETE USING

CERAMIC AGGREGATE AND FLY ASH .This consists of properties of the low strength

concrete,experimental investigations, test results,discussion and conclusion.

The mix design is prepared with IS 10262 1982 Byreffering no. of

journals we have gathered preliminary details for low strength concrete .Feauters of low strength

concrete with ceramic aggregates and fly ash.

The compressive strength of low strength concreteranges from 5 to 10

N/mm2.The flexural strength of low Strength concrete ranges from 1 to 1.2 N/mm

2.

The admixtures like fly ash increase the strength of the concrete along with

Portland cement.In this concrete,fine aggregate is replaced by upto 50 % of fly ash and it has all the

mechanical properties of cement.The ceramic aggregate is the waste product of certamic insulating

factories and fly ash is the by product of thermal power plant .


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INTRODUCTION

At present the majority of aggregate of the materials, Forall construction

applications are obtained from primary resources Such as crushed rock and sand.Since good quality

aggregate are very limited,It has become necessary to study alternative materials for construction.

Factories manufacturing ceramic insulators produce a large amount of

waste.The reuse and recycling of this waste materials are still not a common practice. These waste

materials are disposed in dumping grounds.Many such waste materials are generated now will

remain in the environment for hundreds ,perhaps thousand of years.The creation of non decaying

waste materials,coimbined with a growing consumer population,hasa resulted in waste disposal

crisis.One solution for this crisis lies in recycling waste into useful product.Also fly ashwhich is an

industrial byproduct of thrmal power plant create disposal problem in addition to affecting the

environment.

So the present investigation is carried out to study the properties of low

strength concrete with ceramic waste as coarse aggregate and fly ash as partial replacement for

sand.


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GENERAL ABOUT CERAMIC AGGREGATE

Recent decades have seen a marked upsurge in industrial and economic

growth,contributing to an improved quality of life and well-being for citizens. However, we should

not lose sight of the fact that every production system creates by-products and waste products

which can affect the environment. These effects may occur at any point in the products life-cycle,

whether during the initial phase of obtaining raw materials, during the transformation and

production phase, during product distribution or when the end user must dispose of products which

are no longer required.

As a result, recent years have witnessed rising social concern about the problem of

waste management in general, and industrial waste and waste from the construction industry in

particular. This problem is becoming increasingly acute due to the growing quantity of industrial,

construction and demolition waste generated despite the measures which have been taken in recent

years at European Community, national and regional levels aimed at controlling and regulating

waste management, in accordance with sustainable development policies and the Kyoto Protocol.

The need to manage these wastes has become one of the most pressing issues of our times,

requiring specific actions aimed at preventing waste generation such as promotion of resource

recovery systems (reuse, recycling and waste-to energy systems) as a means of exploiting the

resources contained within waste, which would otherwise be lost, thus reducing environmental

impact. In addition to helping protect the environment, use of such waste offers a series of

advantages such as a reduction in the use of other raw materials, contributing to an economy of

natural resources. Moreover, reuse also offers benefits in terms of energy, primarily when the waste

is from kiln industries (the ceramics industry) where highly endothermic decomposition reactions

have already taken place, thus recovering the energy previously incorporated during production.

Ceramic waste may come from two sources. The first source is the ceramics industry, and this

waste is classified as non-hazardous industrial waste (NHIW). According to the Integrated NationalPlan on Waste 2008-2015, NHIW is all waste generated by industrial The ceramics industry is

comprised of the following subsectors: wall and floor tiles, sanitary ware, bricks and roof tiles,

refractory materials, technical ceramics and ceramic materials for domestic and ornamental use. In

both the European Union and Spain, the scale of production within these subsectors with regard to

total production follows the same trends, where the production of wall and floor tiles represents the


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highest percentage with respect to the total, followed by bricks and roof tiles, and finally, the other

subsectors, as can be seen in Figures 1 and 2.

Ceramicproducts are produced from natural materials containing a high proportion of clayminerals.

Following a process of dehydration and controlled firing at temperatures between700C and

1000C, these minerals acquire the characteristic properties of fired clay


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CERAMICS INDUSTRY WASTE

Ceramic factory waste (figure 3), known as masonry rubble, is not sorted

according to the reason for rejection, which may include: - Breakage or deformation, which does

not affect the intrinsic characteristics of the ceramic material.

Firing defects, due to excessive heat (over-firing) or insufficient heat (under-firing), faults

particularly associated with the use of old kilns and which may affect the physico-chemical

characteristics of the product.

Ceramic products are made from natural materials which contain a high

proportion of clay minerals. These, through a process of dehydration followed by controlled firing

at temperatures of between 700C and 1000C, acquire the characteristic properties of fired clay.

Thus, the manufacturing process involved in ceramic materials requires high firing temperatures

which may activate the clay minerals, endowing them with pozzolanic properties and forming

hydrated products similar to those obtained with other active materials.

Research carried out into the influence of firing temperatures on waste

product properties has found that the chemical and mineralogical composition of ceramic masonry

rubble resulting from incorrect firing temperatures (over- or under-firing) varies significantly fromthat of products obtained from optimal firing conditions. However, the temperature applied (around

900C) is sufficient to activate the clay minerals, with the result that the different rejectsCeramic

masonry rubble must be suitably fine in order to be used as a pozzolanic additive in cement, and

thus must be crushed and ground until reaching the specific surface, or Blaine value, of around

3500 cm2/g. This material presents a chemical composition similar to other pozzolanic materials,


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with a strongly acid nature where silica, aluminium oxide andiron oxide predominate (75.97%), and

with a CaO content of 12.41% and an alkali content of4.22%. Loss through calcination is 3.44%

and sulphate content, expressed as SO3, is 0.79%. Mineralogical composition, determined by X-ray

diffraction, mainly comprises the crystalline compounds quartz, muscovite, calcite, microcline and

anorthite. In order to assess pozzolanic activity, an accelerated method is used in which the

materials reaction overtime with a lime-saturated solution is studied. The percentage of lime fixed

by the sample is obtained through calculating the difference between the concentration of the initial

lime-saturated solution and the CaO present in the solution in contact with the material at the end of

each pre-determined period.

The results, which are shown in Figure 4, demonstrate that ceramic waste

presents pozzolanic activity; at one day, the percentage of fixed lime is 19% of all available lime.

This level of activity is lower than that corresponding to the fumed silica considered, but greater

than that of the fly ash. After longer periods, fixed lime values tend to equal out, and thus after 90

days very similar results are obtained for all three materials considered. It was also established that

the firing temperatures used for producing ceramic material (around 900C) are sufficient to

activate the clay minerals and thus obtain pozzolanic properties. Therefore, in the light of these

results, it can be stated that rejected ceramic material, or ceramic masonry rubble, presents

acceptable pozzolanic properties, since the firing temperatures used in manufacture are ideal for

activating the clays from which they are constituted.

Recycled aggregate

Recycled aggregates can be defined as the result of waste treatment and

managementwhere, following a process of crushing to reduce size, sieving and laboratory analysis,

the waste complies with technical specifications for use in the construction sector and civil

engineering. According to Ignacio (2007) it is not possible to carry out an exhaustive

characterization of all kinds of recycled aggregates. Therefore, this topic will be discussed in more

general terms by looking at concrete aggregates, asphalt agglomerate aggregates and other recycled

aggregates which incorporate aggregates from clean ceramic material waste and aggregates from

mixtures. As mentioned previously, one of the objectives of the new waste reuse and recycling

policies in the construction and industrial sectors is to use recycled aggregates as a substitute for

conventional natural aggregates, with the aim of reducing both use of natural resources

andenvironmental impact caused by dumping.


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CHARACTERISTIC PROPERTIES OF CERAMIC

AGGREGATE:

CHARECTERISTICS CERAMIC

Grading modulus 6.17

Max size (mm) 12.5

Fine content (%) 0.16

Dry sample real density 2.39

Water absorption coefficient 0.55

Elongation index (%) 23

Mix W/C

RATIOCERAMIC WASTE COARSE AGGREGATE

CEMENT

CONTENT

(KG/m3)

SLUMP

TEST

(mm)

COMPRESSIVE

SRENGTH

(Mpg)

DENSITY

(KG/m3

)

M2

M5

M10

0.65

0.55

0.45

285

345

422

40

20

15

15.64

23.51

30.16

2142.20

2035.56

2074.07


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GENERAL ABOUT FLY ASH:

Fly ash is finely divided residue resulting from the combustion of the

powdered coal and transported by flue gases and collected by electrostatic precipitator. In U.K it is

referred as pulverized flue ash. Fly ash is the most widely used pozzolanic material all over the

world.

Fly ash was first used in a large scale in the construction of hungry hourse

dam in America in the approximate amount of 30 per cent by weight of cement. Later on it was

used inCanyon and ferry damsete. In India, fly ash was used in Rihand dam construction replacing

cement up to 15 per cent.

In the recent time, the importance and use of fly ash in concrete has grown so

much that it was almost become a common ingredient in concrete, particularly for making high

strength and high performance concrete. Extensive research has been done all over the world on the

benefit that could be accrued in utilization on fly ash as a supplementary cemintitious material.

High volume fly ash concrete is subject of current interest all over the world.

The use of fly ash as concrete mixer not only extent technical advantages to

the property of concrete but also contribute to environmental pollution control. In India alone we

produce 75 million tone of fly ash per year, the disposal of which has become a serious

environmental problem. The effective utilization of fly ash in concrete making, is, therefore,

attracting serious consideration of concrete technologist and government department.

Secondly, cement is the back bone of the global infrastructural development. It

was estimated that global production of cement is about 1.3 billion tone in 1996. Production of

every tone of cement emits carbon dioxide to the tune of about 0.87 ton. Expressing in another way,

it can be said that 7% world carbone dioxide emission is attribute to Portland cement industry.

Because of the significant contribute to environmental pollution and to the high consumption ofnatural resources like limestone ete.,wecan not go on producing more and more cement. One of the

practical solution to economise cement is to replace with supplementary cementitious material like

fly ash and slag.


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In India, productin of fly ash is nearly as much as that of cement. But our utilization of fly

ash is only 5%. Therefore, the use of fly ash must be popularized for more than one reason.

There are two way that the fly ash can be used ; one way is to intergrid certain percentage of

fly ash with cement clinker at the factory to produce Portland pozzolana cement and the second way

is to use the fly ash as admixture at the time of making concrete at the site of work. The latter

method gives freedom and flexibility to the user regarding the percentage adition of fly ash.

There are about 75 thermal plant in India. The quality of fly ash generetted in different plant

vary from one another to a large extent and hence they are not in a ready to use in condition. To

make fly ash of consistent quality, make it suitable for use in concrete, the fly ash is required to be

further proceed. Such processing arrangement are not available in India.

The quality of fly ash is governed by IS 3812part I2003.The BIS specification limit for

chemical requirement and physical requirement are listed in the below tables.Highfineness,low

carbon content,good reactivity are the essence of good fly ash.Since fly ash is produced by rapid

cooling and solidification of molten ash, a large portion of components comprising fly ash particles

are in amorphous state.The amorphous characteristics greatly contribute to the pozzolanic reaction

between cement and fly ash.One of the important characteristics of fly ash is the spherical form of

particles.This shape of particles improves the floawability and reduces the water demand.The

suitability of fly ash could be decided by finding the dry density of fully compacted sample.

The fly ash is boadly classified into two classes:

CLASS F: Fly ash normally produced by burning anthracite or bituminous coal,

usually has less than 5 % Cao . Class F fly ash has pozzolonic properties only.

CLASS C: Fly ash normally produced by burning lignite or sub bituminous coal.

Some class c fly ash has Cao content in excess of 10 %. In addition to pozzolonic properties, class c

fly ash also possesescementious properties.


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Illustrative properties of fly ash from different sources:

Property/source A B C D E

Specific gravity

Wet sieveanalysis

Specific surface

Lime reactivity

CHEMICALANALYSIS

SiO2

SO3

P2O5

Fe2O3

Al2O3

Ti2

Mn2O3

CaO

Mgo

Na2O

Loss on ignition

pecentage

1.91

16.07

2759

86.8

50.41

1.71

0.31

3.34

30.66

0.84

0.31

3.04

0.93

3.07

5.02

2.12

54.65

1325

56.0

50.03

--

--

10.20

18.20

--

--

6.43

3.20

--

11.33

2.10

15.60

2175

40.3

63.75

--

--

30.92

--

--

--

2.35

0.95

--

1.54

2.25

5.00

4016

79.3

60.10

--

--

6.40

18.60

--

--

6.3

3.60

--

4.90

2.146 to 2.149

51.00(dry)

2800 to 3250

56.25 to 70.31

4559

Traces to 2.5

--

0.64.0

23.33

0.51.5

--

56

1.55

--

1 - 2


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Chemical Requirements:

SL no. Characteristic Reqirement

(1) (2) (3)

a)

b)

c)

d)

e)

f)

g)

h)

Silicon di oxide plus

aluminium oxide percent by

mass

Silicon di oxide per cent bymass

Reactive silica in % by mass

Magnetium oxide per cent by

mass

Total sulphur as sulphur trioxide per cent by mass

Available alkalis, as sodium

oxide per cent by mass

Total chloride present by mass

Loss on ignition

70.0

35.0

20.0

5.0

3.0

1.5

0.05

5.0


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Pysical requirements:

Sl. No Characteristic Requirement

Grade of fly ash

I II

(1) (2) (3) (4)

a)

b)

c)

d)

Fineness Specific surface in

m2/k.g

Lime reactivity Averagecompressive strength in N/mm2

Compressive strength at 28days in N/mm2

Soundness by autoclave test

expansion of specimens, per

cent

320 250

4.5 3.0

Not less than 80 per cent of thestrength of corresponding plain

cement mortar cubes

0.8 0.8

Effect of fly ash on concrete:

Good fly ash with high fineness, low carbon content highly reactive forms only a small

fraction of total fly ash collected. The ESP fly ash collected in chambers I and II are generally very

coarse, non spherical particles showing large ignition loss. They can be called coal ash rather than

fly ash. Such fly ash is not suitable for use as pozzolan and they do not reduce the water demand.

Use of right quality fly ash, results in reduction of water demand for desired slump. With the

reduction of unit water content, bleeding and drying shrinkage will also be reduced. Since fly ash is

not highly reactive, the heat of hydration can be reduced through replacement of part of the cement

with fly ash.

Fly ash when used in concrete , contributes to the strength of concrete due to it spozzolonic

activity .the initial strength of fly ash concrete tends to lower than that of concrete without fly ash.

Due to continued pozzolanic reactivity concrete develops greater strength at later stage


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RAW MATERIALS USED AND THEIR MIXED RATIO:

RAW MATERIALS USED:

The raw materials use for construction of low strength concrete are given below.

Ceramics

Fly ash

Portland slag cement

Sand

Water

MIXED RATIO

Ceramics 20%

Fly ash 50%

Portland cement 10%

Sand 10%

Water 10%


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MIXED DESIGN:

INDIAN STANDARD RECOMMENDED METHOD OF CONCRETE MIX DEIGN

FOR M 10 GRADE OF CONCRETE:

1. Design stipulations:i. Characteristic compressive strength required in field at 28 days = 10 Mpa

ii. Max size of aggregate = 10mm

iii. Degree of workability = 0.38

iv. Degree of quality control = good

v.

Type of exposure = mild

vi. Compacting factor = 0.8

2. Test data for materials:a) Specific gravity of cement [Sc] = 3.15

b) Specific gravity of coarse aggregate[Sca] = [3.90 x 0.7] +[2.86 x 0.3]

= 3.89

c)Specific gravity of fine aggregate [Sfa] = 2.75

d)absolute volume of fine aggregate[P] = 0.40

Approximate sand and water content per cubic metere of concrete for grades uptoM35(Table

no 4 of IS 102621982)

e

Max size of aggregate Water content including

surface water ,per cubic mt.

of concrete[K,g]

Sand as % of total aggregate

by bsolute volume

10 200 40

20 186 35

40 165 30


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e) free surface moisture:

1. coarse aggregate : nil

2.fine aggregate : 2.0 %

f) sieve analysis is shown below:

1.Coarse aggregate

2.Fine aggregate

Seive size

(mm)

Analysis of Coarse

aggregate (% of passing)

Percentage of different fractions Remark

I II I II Combined

(100%)

20

10

4.75

2.36

100

0

--

100

71.20

9.40

60

0

--

--

40

28.5

3.7

--

10

28.5

3.7

--

Conforming

to IS :383--

1970

Sieve sizes Fine aggregate(% passing) Remarks

4.75mm

2.36mm

1.18mm

600micron

300micron

150micron

100

100

93

60

12

2

Conforming to grading Zone

III of table no 4 of IS:385--

1970


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3.TARGET MEAN STRENGTH OF CONCRETE:

Grade of cement = 53 rd grade

Target mean strength = not more than 5%

Fck = fck + 1.65 s

Where s is the standard deviation and it is taken as 3.3 from IS 102621982 .

Fck = 10 + 5.445

= 15.445 Mpa

4.SELECTION OF WATER CEMENT RATIO:

From the figure 2 of IS 16262 -1982 the water cement ratio required for target men

strength of 15.445 Mpa is 0.70

5.SELECTION OF WATER AND SAND CONTENT:

From table no 4 of IS 102621982 grades upto M.35 are given and from that approximate

values are taken.

So, water content = 200 K.g

Sand as % of total aggregate

by absolute volume} = 40 %

and the required water content (W) = 200 lit.


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6..DETERMINATION OF CEMENT CONTENT:

Water cement ratio = 0.70

Water = 200

Cement content (C) = 200/0.70

= 285.71 Kg/m3

7. DETERMINATION OF COARSE AND FINE AGGREGATE:

V = {w + c/se + 1/p fa/sfa}1/1000 (1)

Ca = (1p)/p x fa x Sca/S[fa] (2)

From equation 1 we have

0.97 = {200 + 285.71/3.15 + 1/0.40 fa/2.75} x (1/1000)

0.97 = {200 + 90.70 + fa/1.1} x (1/1000)

0.97 = {220 + 99.77 +fa}/1.1 x (1/1000)

0.97 x 1100 = 220 + 99.77 + fa

Fa = 106722099.77

Fa = 747.23

From equation 2

Ca = (1p)/p x fa x Sca/S[fa]


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= (1 -0.40) /0.40 x 747.23 x (3.89)/275

= 1.5 x 747.23 x 1.42

= 1591.5999 Kg/m3

Hence we have got all the values concerning mixed design and it is listed .

8.THE MIX PROPOTIONS THEN BECOMES:

Water Cement Fine aggregate Coarse aggregate

200 285.71 747.23 1591.5999

0.70 1 2.7 5.67

9.ACTUAL QUANTITIES REQUIRED FOR MIX PER BAG OF CEMENT:

(FOR CONCRETE CUBES AND CONCRETE CYLINDERS)

Volume of the cube = l x b x h

= 15 x 15 x 15

= 3375 Cm3

Volume of the cylinder = r2h

= 3.14 x 7.5 x 7.5 x 30

= 5298.75 Cm3


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Total volume = 3375 +5298.75

= 8673.75 Cm3

For getting actual volume = total volume + 20 %

= (8673.75 x 20)/100

= 1734.75 Cm3

Thus we have obtained the volume for making one cylinder and one cube

= 1734.75 + 8673.75 = 10418.50 Cm3

Volume of concrete needed for one

Cube and one cylinder} (Vc) = 1/sc + (%fa)/sfa + (%ca) /sfa + w/c ratio

Where,

Sc = specific gavityog cement

Fa = fine aggregate

S[fc] = specific gravity of fine aggregate

Ca = coarse aggregate

Sca = specific gravity of coarse aggregate

Hence, Vc = 1/3.15 + 2.70/2.75 + 5.67/2.89+0.7

= 0.3174 +0.9818 +1.9619 + 0.7

So Vc = 3.96 mm

Thus the volume of concrete needed for making one cube and one cylinder

= 3.96 mm


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Weight of cement for one cube and one

Cylinder Wc = (1/Vc) x V

Where,

Vc = volume of concrete for 1 cube and I cylinder

V = volume for making one cylinder and cube

Wc = (1)/(3.96) x 10418.5

= 2.63 Kg

WEIGHT OF FINE AGGREGATE FOR ONE CUBE AND CYLINDER:

= Mix propotion of Fa x weight of cement per one cube and cylinder[Wc]

= 2.7 x 2.63 = 7.10 Kg

WEIGHT OF COARSE AGGREGATE FOR ONE CUBE AND CYLINDER:

= Mix propotion of Ca x mix propotion of Fa

= 5.67 x 2.7

= 15.30 Kg

REQUIRED AMOUNT OF WATER FOR ONE CUBE AND ONE CYLINDER:

= W/C ratio x mix propotion of Fa

= 0.7 x 2.7 = 1.89 Lit.


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VOLUME OF CONCRETE NEEDED FOR MAKING 9 CUBES AND 6 CYLINDERS:

Volume of concrete needed for making 9 cubes

And 6 cylinders} = 3.96 x 7.5

= 29.7 Cm3

WEIGHT OF CEMENT NEEDED FOR MAKING 9 CUBES AND 6 CYLINDERS:

Weight of cement needed for making 9 cubes

And 6 cylinders = 2.63 x 7.5

= 19.73 Kg

WEIGHT OF FINE AGGREGATE FOR 9 CUBES AND 6 CYLINDERS:

Weight of Fa for 9 cubes and 6 cylinders = 7.10 x 7.5 = 53.25 Kg

WEIGHT OF COARSE AGGREGATE FOR9 CUBES AND 6 CYLINDERS:

Weight of Ca for 9 cubes and 6 cylinders = 15.30 x 7.5

= 114.75 Kg

REQUIRED AMOUNT OF WATER FOR 9 CUBES AND 6 CYLINDERS:

Required amount of water for 9 cubes and

6 cylinders} = 1.89 x 7.5 = 14.18 lit


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The above mentioned are all concerning without replacement of ceramic

aggregate and fly ash .In This project we have to replace ceramic aggregate and fly ash instead of

coarse aggregate and cement. Now with replacement are discussed below.

The mixed ratio of the materials added are mentioned earlier and according to that the

weight of cement ,coarseaggregate,fine aggregate changes

WITH REPLACEMENT OF CERAMIC AGGREGATE AND FLY ASH:

WEIGHT OF CEMENT FOR MAKING 9 CUBES AND 6 CYLINDERS:

(with 50 % replacement of Fly ash):

= 19.75 X (50/100)

= 9.875 Kg

WEIGHT OF FLY ASH WHICH HAS TO BE ADDED:

= 19.759.875

= 9.875 Kg

WEIGHT OF FINE AGGREGATE NEEDED FOR MAKING 9 CUBES AND 6

CYLINDERS: (no replacement) = 53.25 Kg

WEIGHT OF COARSE AGGREGATE :(With replacement of 20 % ceraic aggregate)

= 114.75[114.75 x (20)/(100)]

= 91.8 Kg

WEIGHT OF CERAMIC AGGREGATE NEEDED:

= 114.7591.8

= 22.95 Kg

REQUIRED AMOUNT OF WATER: = 14.18 Lit.


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MANUFACTURING PROCESS OF CERAMIC AND FLY ASH MIXED CONCRETE

(FLOW CHART)

ILLUSTRATION OF STEPS OF MANUFACTURING OF CERAMIC CONCRETE:

Raw materials:

The raw materials used for the purpose of mixing are going to be discussed here and

they are

a)

Portland slag cement

b) Fine aggregate

c) Coarse aggregate

d) Ceramic aggregate

e) Fly ash

RAWMATERIALS

MIXING

SLUMP TEST SAMPLING

CURING

CUBE TEST &CYLINDER

TEST


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The mixed proportions of the above are already discussed and according to that ratio

they are mixed

The ceramic aggregate for coarse materials are taken and they are crushed to small

pieces by hammer.These small pieces are then fed to a vibrator.

Vibrator is a compacting device used for the removal of entrapped air from the

concrete. Vibrator are applied only for ordinary concrete there are various methods of

vibrations by using various types of vibrators such as internal vibrator, external vibrator,

table vibrator, platform vibrator , surface vibrator.

Here we are using a table vibrator as it is best suitable here. This is the special case

of form work vibrator, where the vibrator is clamped to the table or table is mounted on

springs which are vibrated transferring the vibrations to the table. They are commonly used

for concrete cubes.this are adopted mainly in labortaries.

MIXING:

Through mixing of the materials is essential for threproduction of uniform concrete.

The mixing should ensure that mass becomes homogeneous, uniform in colour

andconstitency . There are two methods adopted for concrete mixing they are

a) Hand mixing b) machine mixing

Machine mixing is adopt for larger mixing. Mixing of concrete is almost

invariably carried out by machine, for reinforced concrete work and for medium or for large

scale mass concrete work. Machine mixing is not only efficient, but also economical, when

the quantity of concrete to be produced is large. Since in here the quantity is not so large and

hence we are adopting hand mixing

Hand mixing is practiced for small scale unimportant concrete works. As the mixing

cannot be through and efficient, it is desirable to add 10 % more cement to cater for the

inferior concrete produced by this method

Hand mixing should be done over an impervious concrete or brick floor of

sufficiently large size to take one bag of cement. Spread out the measured quality of coarse


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aggregate and fine aggregate in alternate layers. Pour the cement on top of it, and mix them

dry by shovel, turning the mixture over and over again until uniformity of colouris achieved.

This uniform mixture is spread out in thickness of about 20 cm. Water is taken in a water-

can fitted with a rose-head and sprinkled over the mixture and simultaneously turned over .

This operation is continued till such time a good uniform, homogeneous concrete is

obtained. It is of particular importance to see that water is not poured but it is only

sprinkled. Water in small quantity should be added towards the end of the mixing to get the

just required consistency. At that stage, even a small quantity of water makes difference.

SLUMP TEST:

Slump test is the most commonly used method of measuring consistency of

concrete which can be employed either in laboratory or at site of work. It is not a suitable

method for very wet or very dry concrete. It does not measure all factors contributing to

workability, nor is it always representative of placability of the concrete. However, it is

used conveniently as a control test and gives an indication of the uniformity of concrete

from batch to batch. Repeated batches of the same mix, brought to the same slump, will

have the same water content and water cement ratio, provided the weight of aggregate,

cement and admixtures are uniform and aggregate grading is within acceptable limits.

Additional information on workability and quality of concrete can be obtained by observing

the manner in which concrete slumps. Quality of concrete can also be further assessed by

giving a few tappings or blows by taping rod to the base plate. The deformation shows the

characteristics of concrete with respect to tendency for segregation.

The apparatus for conducting the slump test essentially consist of a metallic

mould in the form of a frustum of a cone having the internal dimensions as under :

Bottom diameter : 20 cm

Top diameter : 10 cm

Height : 30 cm

It is seen that the slump test gives fairly good consistent results for a plastic-

mix. This test is not sensitive for a stiff-mix. In case of dry mix, no variation can be detected


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between mixes of different workability. In the case of rich mixes, the value is often

satisfactory, their slump being sensitive to variations in workability. IS 456 of 2000 suggests

that in the very low category of workability where strict control is necessary, for example,

pavement quality concrete,(PQC) measurement of workability by determination of

compacting factor will be more appropriate than slump and a value of 0.75 to 0.80

compacting factor is suggested.

CURING:

Curing methods may be devided broadly into four categories :

a) Water curing

b) Membrane curing

c) Application of heat

d) Miscellaneous

Water curing:

This is far the best method of curing as it satisfies all the requirements of curing namely,

promotion of hydration, elimination of shrinkage and absorption of the heat of hydration.It

is pointed out that even if the membrane method is adopted,it is desirable that a certain

extent of water curing is done before the concrete is covered with membranes.Water

curing can be done in following ways.

a) Immersion

b) Ponding

c) Spraying or Fogging

d) Wet covering.

In here we are adopting water curing method as it is best suitable and here we are

immersing the concrete cubes in water and curing is done for 24 hours.


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SAMPLING:

The sampling is the process of manufacturing of the testing of the samples.And in here we

are making cubes and cylinders samples.The dimension of each are listed below

1) Cube 150 mm x 150 mm x 150 mm

2) Cylinders 150 mm x 300mm x 150 mm

CUBE SAMPLE:

Here a cube mould of the dimensions 150 mm x 150 mm are taken and it is cleaned

to avoid dust particles.Then the mixed concrete are put into it and they are well compacted

inside the mould using compacting devices and all the voids are avoided .Then all the

concrete will be correctly filed in it. On the next day actually after 24 hours the cube mould

is removed and then we are able to get a cube, the cube is then cleaned.This is the process of

cube sample manufacturing.

CYLINDER SAMPLE:

Here a cylinder mould of the dimensions 150 mm x 150 mm x 150 mm are taken and it is

cleaned to avoid dust particles.Then the mixed concrete are put into it and they are well

compacted inside the mould using compacting meachines and all voids are avoided, then all

the concrete will be correctly filled in it.On the next day actually after 24 hours the cylinder

mould is removed and then we are able to get the cylinder, the cylinder is then cleaned and

thus a cylinder sample is obtained.

By similar process, 9 cubes are prepared using 9 cube moulds and 6 cylinders are

prepared using 6 cylinder moulds.After that tests are made on these sample


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GENERAL ABOUT CUBE TEST AND CYLINDER TEST:

The main function of the manufacturing of cubes and cylinders is inorder to check

the strength of the concrete used in it. And for the above purpose two tests have been

adopted and they are,

1) Compression Test

2) Flexural tensile test

COMPRESSION TEST:

Compression test is most common test conducted on hardened concrete, partially

because it is easy to test perform, partially because most desirable characteristic property of

concreteare qualitatively related to its compressive strength.

Compression test is carried out of specimen cubical or cylindrical in shape. Prisms

are also some time used, but it is not common in our country. Sometime the compression

strength of concrete is determined using part of beam test in flexure. The end part of beam

left intact after failure in flexure because the beam is usually in square cross section, the part

of beam could be used to find out the compressive strength.

The cube specimen of size 15x15x 15 cm . If the large nominal size of the aggregate

does not exceed 20 mm, 10 cm size cube may also be used as an alternative. Cylindrical test

specimens have 15 cm in dia and 30 cm long. Smaller test specimen may be used but a ratio

of dia of the specimen to maximum size of the aggregate, not less than 3 to 1 maintained in

aggregate.

FLEXTURAL TENSILE TEST:

Direct measurement of tensile strength of concrete is difficult. Neither specimen

nor tensile apparatus have been designed which assure uniform distribution of the pull

applied to the concrete. While a number of investigation involving the correct measurement

of tensile strength made, beam test are found to be dependable to measure flexural strength

property of concrete.


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The value of the modulus of the repture depend on on the dimension on the beam

and manner of loading. In the central point loading, maximum fiber strength will below the

point of loading where bending moment is maximum. In the case of cylindrical two point

loading , the critical crake may appear at any section , not strong enough to resist the

stresswithin the middle third, where the bending moment is maximum. It can be expressed

in two point loading will yield a lower value of modulus of repture than the central pointing

of loading.

The modulus should be of metal preferable steel or cast iron and the metal should

be sufficient thickness to prevent spreading. The modulus should be constructed with the

longer dimensionhorizontally and in a such a manner as to facilitatethe removal of the

modulus specimen without damage.

The tempering bar should be a steel bar weighing 2 kg, 40 cm long and should

have a ramming face 25 mm square.

The testing machine may be any reliable type of sufficient capacity for the test and

capable of applying the load at the rate specified. The bed of test specimen should be

provided with two steel roller, 38mm in diameter on which the specimen is to be supported ,

and these roller should be mounted that the distance from center to centeris 60 mm for 15

cm specimen or 40 cm for 10 cm specimen. The load is divided equally between to loading

roller and all loaded are mounded in a such a manner that load is applied axially and without

subjecting specimen to any torsional stresses or restrains.

USAGE OF UNIVERSAL TESTING MEACHINE:

The bearing surfaces of the supporting and loading rollers are wiped clean, and any

loose sand or other material removed from the surfaces of the specimen where they are to

make contact with the rollers. The specimen is then placed in the machine in such a mannerthat the loads is applied to the uppermost surface as cast in the mould, along two lines

spaced 20.0 or 13.3 cm apart. The axis of the specimen is carefully aligned with the axis of

the loading device. No packing is used between the bearing surfaces of the specimen and the

rollers. The load is applied without shock and increasing continuously at a rate such that the

extreme fibre stress increases at approximately 0.7 kg/sq cm/ min that is, at a rate of loading


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of 400 kg/min for the 15.0 cm specimens and at a rate of 180 kg/min for the 10.0 cm

specimen. The load is increased until the specimen fails, and the maximum load applied to

the specimen during the test is recorded. The appearance of the fractured faces of concrete

and any unusual features in the type of failure is noted.

The flexural strength of the specimen is expressed as the modulus of rupture fb

Which if a equals the distance between the line of fracture and the nearest support,

measured on the center line of the tensile side of the specimen, in cm, is calculated to the

nearest 0.05 Mpa as follows :

fb = (p x l ) / (b x d2)

When a is greater than 20.0 c.m for 15.0 c.m specimen or greater than 13.3

c.m for a 10.0 c.m specimen, or

fb = (3p x a) / ( b x d2)

When a is less than 20.0 cm but greater than 17.0 cm for 15.0 specimen, or

less than 13.3cm but greater than 11.0 cm for a 10.0 cm specimen where

b = measured width in cm of the specimen,

d = measured depth in cm of the specimen at the point of failure,

l = length in cm of the span on which the specimen was supported

p = maximum load in kg applied to the specimen.

If a is less than 17.0 cm for a 15.0 cm specimen, or less than 11.0 cm for a

10.0 cm specimen, the result of the test be discarded.

As mentioned earlier, it is difficult to measure the tensile strength of concrete

directly. Of late some methods have been used with the help of epoxy bonded end pieces to

facilitate direct pulling. Attempts have also be made to find out direct tensile strength of


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concrete by making briquette of figure 8 shape for direct pullig but this method was

presenting some difficulty with grip and introduction of secondary stresses while being

pulled.

Whatever may be the methods adopted for finding out the ultimate direct

tensile strength, it is almost impossible to apply truly axial load. There is always some

eccentricity present. The stress are changed due to eccentricity of loading. These may

introduce major error on the stresses developed regardless of specimen size and shape.

The third problem is the stresses induced due to the grips. There is a

tendency for the specimen to break near the ends. This problem is always overcome by

reducing the section of the central portion of the test specimen . The method in which steel

plates are glued with the epoxies to the ends of the specimen, eliminates stresses due to

gripping , but offers no solution for the eccentricity problem.

All direct tension test methods require expensive universal testing machine.

This explains why these tests are not used on a routine basis and are not yet standardized.

A COMPARISON BETWEEN CUBE AND CYLINDER STRENGTH:

It is difficult to say wheather cube test give more realistic strength properties

of concrete or cylinders give a better picture about the strength of concrete.However it can

be said that the cylinder is less affected by the end strains caused by platents and hence it

seems to give more uniform results than cube.Therefore the use of cylinder becomes more

popular particularly in research laboratories.

Cylinders are cast and tested in same position, whereas cubes are cast in one

direction and tested in the other direction. In actual structures in the field, the casting and

loading is similar to that of the cylinder and not like the cube. As such, cylinder simulates

the condition of the actual structural member in the field in respect of direction of load.

The points in favor of the cube specimen are that the shape of the cube

resembles the shape of the structural members often met with on ground. The cube does not

require capping, whereas cylinder requires capping.The capping material used in case

cylinder may influence to some extent the strength of the cylinder.


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TEST MADE ON SAMPLE: (TABULATION)

VALUES OBSERVED DURING COMPRESSION TEST:

Sl .no Mix W/C ratio Compression strength

3 days 7 days 28 days

1 M 10 0.65

2 M 10 0.55

3 M10 0.45

VALUES OBSERVED DURING TENSILE TEST:

Sl .no Mix W/C ratio Tensile strength

3 days 7 days 28 days

1 M 10 0.65

2 M 10 0.55

3 M10 0.45


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CONCLUSION:

In our project we studied and analyzed about LOW STRENGTH

CONCRETE USING CERAMIC AGGREGATE AND FLY ASH and their various

characteristics in the field. We collected the information by browsing various website in

internet, visiting number of chambers general library, construction shop and other colleges

libraries to collect various reference books.

Specimens are made and test like compressive strength, flexure strength and

split tensile test are conducted and their results are tabulated respectively.

A detailed analysis of the results obtained in the various assays has lead to

the following initial conclusions.

Recycled aggregates obtained from industrial waste produced by the

sanitary ceramics industry are suitable for manufacture of concrete.

Recycled concrete obtained through partial substitution of natural coarse

is suitable for structural purposes.

Fly ash the next material used are also a waste material which obtained in

thermal power plant. These fly ash causes great disposal problems as it

may contain radioactive materials. By taking this , a great amount of

radioactive waste material can also be replaced.

Now coming to the total mixed concrete, a large amount of coarse

aggregate and sand are needed. By this project these two can be very

much reduced.Thus the unwanted wastage of sand ,coarse aggregate can

be made possible.


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The main advantage is that all the usual mixing materials in concrete are

very much expensive and by the usage of the mentioned low strength

concrete the expense of whole construction process can be reduced and

thus profitable.

From the test result and discussion, the following conclusions are drawn from the

study on ceramics waste as coarse aggregate and fly ash as fine aggregate , they are

applicable for the

range of parameters and materials in this study. Ceramics waste can be transformed into

useful coarse aggregate and fly ash as fine aggregate. The properties of ceramics waste

coarse aggregate are within the range of the values of concrete-making aggregate and they

are not significantly different from those of conventional concrete. This research work is the

basic for further experiment on normal concrete with the use of ceramics waste.

The use of Low Strength Concrete in the field results in providing more advantage.

Hence it is a trend setting material in this developing modern technology and their growth in

the scientific method of construction.

Thus we have analyzed various characteristics of the LOW STRENGTH

CONCRETE in the best and more attracting way which appears to our knowledge and

most economical.


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REFFERENCE:

[1]M.S.Shetty . Concrete Technology Theory and practice. S.Chand & Company Ltd.

[2] Binici, H. Effect of crushed ceramic and basaltic pumice as fine aggregates on concrete mortars

properties. Construction and Building Materials, vol. 21 (2007), 11911197

[3] Correia, J.R.; de Brito,J.; Pereira, A.S. Effects on concrete durabi[lity of using recycled ceramic

aggregates.Materials and Structures, vol. 39 (2006), 169-177

[4] De Brito,J.; Pereira, A.S.; Correia, J. R. Mechanical behaviour of non-structural concrete made

with recycled ceramic aggregates. Cement and Concrete Composites, vol. 27 (2005), 429-433

[5] RM. Senthamarai, P.Devadas Manoharan, Concrete with ceramic waste aggregate, Cem Concr

compos 27 (2005) 910-913

[6] How-Ji chen, Tsong Yen, Kuan-Hung Chen, Use of building rubbles as recycled aggregates,

Cem Concr Res 33 (2003) 125-132

[7] Gemma Rodriquez de Sensale, Strength development of concrete with rice-husk ash, Cem

Concr Compos 28 (2006) 158-160

[8] Khaloo AR. Crushed tile coarse aggregate concrete. Cem. Concrete Aggregate 1995; 17(2):

119-125

[9] Binici, H. (2007). Effect of crushed ceramic and basaltic pumice as fine aggregates on concrete

mortars properties. Construction and Building Materials, vol. 21, Issue 6, (June 2007), 1191

1197, 0950-0618.

[10] ASTM International Standard ,ASTM C 618 -05 ,Standard Test Method for Coal fly ash and

raw or calcinated natural pozzolan for use in concrete.


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[11] Owens , P.L. Fly ash and its usage in concrete. Concrete: The journal of the concrete society,

1979.13: 2126

[12] Helmuth R, Fly ash in cement and concrete, Portland cement association ,1987.

[13] Malahothra, V.M., Ramezanianpour,A.A., Fly ash in concrete, CANMET ,1984.

[14] Minnick, L.J., Webster , WC., and Purdy, E.J., Predictions of the effect of fly ash in Portland

cement mortar and concrete ,Journal of materials,1971,6:163187

[15] Philleo, R.E., Recent developments in pozzolan specifications.Proceedings , 2nd

International

Conference on the use of fly ash silica fume slag and natural pozzolans in concrete

,Madrid,Spain,Apr.21 - 25,1986, supplementary paper 27.

[16] Brizzi ,A., Puccio , M., and Valenti, G.L., Corelations between physic chemical

characteristics of fly ash and its technical properties for use in concrete,Proceedings, 3rd

CANMET/ACI International Conference on the usuage of fly ash ,Silica fume, Slag, and Natural

pozzolans in concrete,Trondheium,Norway,June 18 -23 ,1989, Supplementary paper 139

[17] ASTM International Standard ,ASTM C 311 -05 ,Standard Test Method for sampling and

testing fly ash or natural pozzolans for use in Portland cement concrete.

[18] IS 10262 1982 ., BUREAU OF INDIAN STANDARD

[19] Senthamarai, RM.; Devadas Manhoharan, P. Concrete with ceramic waste aggregate. Cement

& Concrete Composites, vol. 27 (2005), 910-913.

[20] Pereira Goncalves, J. Use of ceramic industry residuals in concrete. REM: R. Esc. Minas,

Ouro Preto, octubrediciembre 2007, n 64, 639644

[21] Cachim, P.B. (2009) Mechanical properties of brick aggregate concrete.


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PICTORIAL REPRESENTATION:

FLY ASH SAMPLE PORTLAND POZZOLANO CEMENT

CERAMIC AGGREGATE COARSE AGGREGATE


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FINE AGGREGATE

MIXING


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HAND MIXING

COMPACTING

CUBESDAY 1


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CUBESDAY 2

CUBESDAY 3


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CYLINDERSDAY 1

CYLINDERSDAY 2


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CYLINDERSDAY 3

CURING


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TOTAL CUBES AND CYLINDERS

STRENGTH TESTING USING UNIVERSAL TESTING MEACHINE


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kashyap main project 1

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