Overview of Partial Replacement of Concrete With Partial Replacement of Fine Aggregate By Pond Ash.

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Overview of Partial Replacement of Concrete With Partial Replacement of Fine Aggregate By Pond Ash.

Mr. Chhajed Samaksh R.

PG Student,

Civil Engg.Dept SNDCOE & Rc Yeola

[email protected]

Dr. R.S. Kale Associate Professor

Civil Engg.Dept SNDCOE & Rc Yeola

[email protected]

ABSTRACT

Power consumption is increasing day by day for utilization.

Power is generated from different power plants such as Thermal power plants, hydraulic power plants, solar power plants and etc. About 70- 75% of total power generated in India is produced by coal-based thermal power plants. The main source of power generation in thermal power plants is Coal. When combustion of Coal occurs in the power plant, Ash is produced as a by-product which is an Industrial waste.

This ash is of different forms such as Fly ash, Bottom ash and Pond ash. A major problem arises on the disposal of this industrial waste. As days go on more coal is utilized and more ash is made ready for the disposal, so this becomes a serious problem. These industrial wastes are to be utilized in different fields such as construction, to minimize its disposal problems.

In this study Pond ash is utilized as a partial replacement of fine aggregate (Natural sand) in concrete. In this investigation fine aggregate are replaced by pond ash by 0%, 10%, 20%

and 30% by weight of fine aggregate to determine the strength properties. The Casting of cubes and cylinders were done to determine the compressive strength and split tensile strength respectively, for 7, 28, 56 and 90 days of curing. It is found by the study that it is possible to use pond ash up to 20%

replacement of Fine aggregate for M30 grade of concrete without compromising strength.

Keywords

Pond ash(PA), Artificial Sand(AS), Fine aggregate(FA), Concrete mix, Strength properties.

1. INTRODUCTION

Use of waste and by-products in concrete will lead to green environment and such concrete can be called as “Green Concrete”. There are various types of waste materials that can be considered for usage in concrete. The most commonly used waste materials to replace sand and cement in concrete are Fly Ash, Rice Husk Ash, Blast Furnace Slag, Red Mud and Phosphor, gypsum, Silica Fume, Fumed silica, Crushed glass, Eggshells. The waste products used to replace coarse aggregate in concrete are Palm Oil Shell Aggregate for Lightweight Aggregate Concrete, Crushed Ceramic, glass, waste wood, crushed concrete aggregate. The current annual production of coal ash worldwide is estimated around 600 million tonnes. The disposal of fly ash will be a big challenge to environment, especially when the quantum increases from the present level. Hence worldwide research work was focused to find alternative use of this waste material and its use in concrete industry is one of the effective. Increase in demand and decrease in natural resource of fine aggregate for the production of concrete has resulted in the need of identifying a new source of fine aggregate. The possibility of utilization of thermal power plant byproduct pond ash as replacement to fine aggregate in concrete is taken into consideration. Effective utilization of ponded ash is very

essential to reduce the environmental problems caused by the accumulation of pond ash. If it is found suitable for construction industry large scale utilization of pond ash would be possible and this will become a major contribution factor for reducing pollution. Future more a precious Natural resource as sand is becoming scare and quarrying of sand has been restricted in many places. This has lead to look for possibility of partial replacement of sand by pond ash without compromising on strength

1.1 Fly Ash and Pond Ash.

FA and PA is an end product (waste) of thermal power plants, FA is a very finer as compared to PA, a Coarser and porous material which falls to bottom of furnace is called as bottom or PA then it is transported to ash pond by mix with water, for an easy flow and it will not fly, so it is also known as wet bottom ash. A pond as is crystalline in nature. The FA and PA has pozzolanic properties that’s why this type of FA and PA has led to a greater research in utilization in replacement to a cement and fine aggregate by FA and PA.

1.2 Properties of fly ash and pond ash:

Coal ash is a by-product generated from the process of coal combustion at high temperature over 1600°c at the coal-fired power plants. Coal ash thus produced can be divided into fly ash and bottom ash. The 20 percent of total ash produced is dry bottom ash, a dark gray, granular, porous, material that is collected in a water-filled hopper at the bottom of the furnace.

Coarser ash is mixed with water and pumped out in the form of slurry to large pond and hence known as pond ash. It is generally accepted that the different size fractions of ash obtained either directly from the various stages of collection in the Electro- Static Precipitator (ESP) or separated in the laboratory using classifiers or sieves exhibit no greater difference in their characteristics in terms of their physical, chemical, mineralogical and also morphological properties.

1.3 Objectives of study

 To establish alternative for FA with partial use of Pond Ash in concrete.

 To make a productive use of waste pond ash which has harmful effect on environment.

 To study properties of wet concrete using pond ash as partial replacement of fine aggregates.

 To study strength properties after partially replacing fine aggregate with Pond ash for M30 grade of concrete.

 To compare the compressive, flexural and tensile strength of PA replaced concrete mix with concrete mix without pond ash.

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Table No 1. Chemical properties of fly/pond ash

2. MATERIAL AND METHODS

In this investigation fine aggregate is replaced by pond ash in concrete using four different mix proportions for M30 grade concrete. The mix design is done as per BIS 10262:2009 and IS456:2000 and the quantities of ingredient have been estimated and accordingly concrete cubes and cylinders and as per standard procedure are prepared and tested and the results for compressive strength and split tensile strength are obtained and analyzed. In this experiment fine aggregate is replaced by pond ash in varying percentage such as 0%, 10%, 20% and 30%. 12 cubes and 12 cylinders are casted for each percentage which are designated as Mix1, Mix2, Mix 3 and Mix 4 respectively. All the specimen of each mix are tested for compressive strength and split tensile strength after 7 days, 28 days, 56 days and 90 days. The ingredients of concrete i.e.

cement, fine aggregate (River sand & Crushed sand), coarse aggregate are tested before use in concrete. Pond ash is also tested before use in concrete. The relevant Indian Standard codes were followed for conducting various tests on the material.

Cement: The cement used in this experimental work is “53 grades Ordinary Portland Cement”. Properties of cement are tested as per IS 12269 – 1987.

Aggregates: Natural sand from Kopargoan (Godavari) river is taken for this experimental investigation. Various tests such as specific gravity, water absorption, moisture content, sieve analysis etc. have been conducted on C.A. & F.A. Crushed black trap basalt rock of size 10mm down was used as coarse aggregate. The results of sieve analysis confirm the requirement of gradation as per I.S. 383-1970.

Pond Ash: Pond ash (process by Dirk India Pvt. Ltd., Nashik) is used in concrete in dry granular form. Color of Pond ash is dark gray

.

Table No 2. Physical Properties of Pond ash

2.1 Concrete mix design of M30 grade:

 Determination of target mean strength of concrete.

 Determination of water cement ratio.

 Determination of water content.

 Determination of cement content.

 Determination of volume of CA and FA.



Table No 3. Quantity of Materials per Cubic Meter of Concrete for M30

Water Cement FA CA

175 388.88 668.70 1160.08

0.45 1 1.72 2.98

So mix proportion for M30 grade is 1:1.72:2.98

2.2 Schedule of Casting

The specimens were used cubes, specimens specially prepared to measure compressive strength. Dimensions of each test specimen are as under:

Cube: 150 mm x 150 mm x 150 mm Beam: 700 mm x 150 mm x 150 mm Cylinder: 300 mm x 150 mm

 Batching, Mixing and Casting of M30 grade concrete Specimens.

Test to be conducted on harden concrete specimens:

compressive strength, splitting tensile strength and flexural strength by beam model at the ages of 7, 28, 56 and 90 days.

Table No 4. Quantity required for 48 No. of cubes and 48 No. of cylinder

Material

Quantity required for 48

cubes (kg)

Quantity required for 48

cylinders (kg)

Cement 77.11 117.46

FA 127.47 202.03

CA 220.85 350.03

Water 33.35 lit 52.86 lit

PA 19.13 30.3

AS 19.14 30.3

Sr.

No. Compounds %

Composition

1.

Silicon di oxide (SiO2) plus, Aluminium oxide (Al2O3) Plus, Iron

Oxide

79.97

2. Silicon di oxide (SiO2)

percent by mass 36.22

3. Magnesium oxide (MgO)

percent by mass 2.73

4.

Total Sulphur as Tri- oxide (SO3) percent by

mass

0.69

5.

Available alkalis as Sodium oxide (Na2O3)

percent by mass

2.12

6. Loss on ignition percent

by mass 6.84

7. Moisture content percent

by mass 1.78

Sr. No. Properties Value

1 Specific gravity 2.4

2 Water

absorption 21%

3 Fineness

modulus 2.79

724 2.3 Preliminary testing on materials:

Cement: Result obtained in preliminary testing of cement is obtained is shown in Table5. The obtained results meet requirements as per IS.

Table No 5. Physical properties of Cement Sr.

no. Description Requirement

as per IS Results

1 Fineness of

cement 0-10% 3%

2 Specific

gravity - 3.15

3 Standard

consistency - 33%

4

Initial setting time Final setting

time

30 min 600 min

47 min 420 min

5 Soundness

test 10.00 MM 3.0 mm

6

Compressive strength 7

days

40.0 N/mm² 41.6 N/mm²

Fine Aggregate: Various tests conducted on fine aggregate is shown in Table 6. The obtained results meet requirements as per IS.

Table No 6. Physical properties of Fine Aggregate

Sr. no. Properties Results

1 Particle shape, size Round, 4.75 mm

2 Fineness modulus 2.683

3 Silt content 3.3%

4 Specific gravity 2.72

5 Bulk density 1723 Kg/m³

6 Surface moisture Nil

Coarse Aggregate: Various tests conducted on coarse aggregate is shown in Table 7. The obtained results meet requirements as per IS.

Table No 7. Physical properties of Coarse Aggregate

Sr. no. Properties Results

1 Particle shape, size Angular , 20 mm

2 Fineness modulus 6.057

3 Specific gravity 2.74

4 Water absorption 2.835 %

5 Moisture content Nil

6 Bulk density 1620 Kg/m³

Pond ash: Various tests conducted on pond ash is shown in table. 8.

Table No 8. Physical properties of pond ash

Sr. No. Properties Value

1 Specific garvity 2.4

2 Water absorption 21%

3 Fineness modulus 2.79

3. RESULT AND ANALYSIS

Experimental Investigation carried out for determination of Compressive strength, Flexural strength and Split tensile strength of concrete with varying percentage of pond ash. The test results of 7, 28, 56 and 90 days compressive strength, flexural test and split tensile test are determined. The details of test on harden concrete are described below:

Test on hard concrete: The tests on hard concrete were conducted for 7, 28, 56 and 90 days for compressive strength using concrete cube specimens. The flexure strength of concrete with pond ash is going to determine by using beam specimens for 28, 56 and 90 days. Split tensile strength of concrete is to determine taking concrete cylinder specimens.Till date the up to 56 days strength of the concrete cube specimens, beam specimens and cylinder were conducted for control concrete specimens and for varying percentage of pond ash.

The Table 9 and Table 10 given below shows the results of 7, 28, 56 and 90 days compressive strength and split tensile strength of control concrete specimens and concrete with pond ash. Table 11 shows the result of 28 days flexural strength for control concrete specimens and concrete with pond ash.

Table No 9. Result of Compressive Strength of Pond Ash Replacement In Concrete at 7 Days, 28days, 56days and

90 days.

Sr no

Mix designation

% of PA in conc-

rete

Avg. compressive strength (N/mm²) 7

days 28 days

56 days

90 days

1

Mix-1 PA:AS:NS

0:0:100

0% 22.2 2

33.3

3 35 37.3

3

725

2

Mix-2 PA:AS:NS

10:20:70

10% 21.1 8

32.1 5

33.3 3

35.5 6

3

Mix-3 PA:AS:NS

20:20:60

20% 20.8 9

30.5 2

32.4 4

34.5 6

4

Mix-4 PA:AS:NS

30:20:50

30% 19.1 1

29.3 3

30.0 7 31.4

Fig. No.1

.

From the above study it can be concluded that compressive strength increases at all ages but lower than control concrete mix. However there is reduction in compressive strength by 4.74 % for 10% PA replacement, 8.73% for 20% PA replacement and 15% for 30% PA replacement as compared to concrete mix without pond ash.

Table No 10. Result of Split Tensile Strength of Pond Ash Replacement In Concrete at 7 Days, 28days, 56days and

90 days.

Sr no

Mix designation

% of PA in conc-

rete

Avg. Split tensile strength (N/mm²) 7

days 28 days

56 days

90 days

1

Mix-1 PA:AS:NS

0:0:100

0% 2.24 2.43 3.1 3.22

2

Mix-2 PA:AS:NS

10% 2.15 2.3 2.7 3.12

10:20:70

3

Mix-3 PA:AS:NS

20:20:60

20% 2.01 2.2 2.6 3.03

4

Mix-4 PA:AS:NS

30:20:50

30% 1.82 2.1 2.2 2.67

Fig. No.2

.

From the above study it can be concluded that tensile strength increases at all ages but lower than control concrete mix.

However there is reduction in tensile strength by 3.10 % for 10% PA replacement, 5.9% for 20% PA replacement as compared to concrete mix without pond ash.

Table 11. Result of Flexural Strength of Pond Ash Replacement In Concrete at 28days.

Sr. No Mix designation

% of PA in concrete

Flexural strength (N/mm²)

28 days

1

Mix-1 PA:AS:NS

0:0:100

0% 6.51

2

Mix-2 PA:AS:NS

10:20:70

10% 6.24

3

Mix-3 PA:AS:NS

20:20:60

20% 5.84

0 5 10 15 20 25 30 35 40

7 days 28 days

56 days

90 days Compressive strength (N/mm2)

No . of Days

Mix- 1 Mix- 2 Mix- 3

Mix- 4 0

0.5 1 1.5 2 2.5 3 3.5

7 days 28 days

56 days

90 days Split tensile strength (N/mm2)

No . of Days

Mix- 1 Mix- 2 Mix- 3 Mix- 4

726

4

Mix-4 PA:AS:NS

30:20:50

30% 4.51

Fig. No.3

.

From the above study it can be concluded that flexural strength increases at all ages but lower than control concrete mix. However there is reduction in flexural strength by 2.7 % for 10% PA replacement, 6.7% for 20% PA replacement as compared to concrete mix without pond ash.

CONCLUSION

 It is found by the study that it is possible to use pond ash up to 20% replacement of FA for M30 grade of concrete without compromising strength.

 The workability of pond ash concrete decreases with the increase in pond ash content due to increase in water demand.

 It is found by the study that compressive strength of PA replaced concrete increases at all stages, however there is reduction in corresponding compressive strength by 4.74

% for 10% PA replacement, 8.73% for 20% PA replacement as compared to concrete mix without pond ash.

 Splitting tensile strength of concrete improved on use of pond ash as partial replacement of sand.

 It is also found that flexural strength of 20% replacement pond ash concrete is within permissible limit as per IS recommendation.

 Use of pond ash as partial replacement of FA can reduces the cost of construction .For 10% replacement of pond ash and artificial sand, saving in cost is 1.16% and that for 20% and 30% PA replacement is 1.57% and 2%

respectively.

REFERENCES

[1] P. Aggarwal, Y. Aggarwal and S.M. Gupta, “Effect of bottom ash as replacement of fine aggregate in concrete,” Asian Journal of Civil Engineering (Building and Housing) vol. 8, No 1 (2007), pp49-62.

[2] Ashish Kumar Bera et al., (April,07), “compaction characteristics of pond ash”, Journal of materials in Civil Engineering‟ , 19(4), pp 349-357.

[3] Arumugan k Ivanovna, Jamesmanohar, “ A Study on Characterization and use of Pond Ash as Fine Aggregate in concrete” International journal of Civil and structural Engineering Volume 2, No2, 2011.

[4] James Manohar D, Arumugam K and Ilangovan R, “ A study on characterization and use of pond ash as fine aggregate in concrete,”International journal of civil and structural engineering volume 2, No 2, 2011” pp 466- 474.

[5] R Narendra and B.K. Narendra, “Characterization of pond ash as fine aggregate in concrete, “Proceedings of International Conference on Advances in Architecture and Civil Engineering (AARCV 2012), 21st - 23rd June 2012, pp119-125.

[6] R. S. Bang, M. Ghugal and K. Pateriya, “Strength performance of pond ash concrete.” International Journal of Earth Sciences and Engineering, volume 05, No 01, February 2012, pp108-185.

[7] IS 456: 2000, Indian Standard Code of Practice for Plain and Reinforced Concrete, Bureau of Indian Standards.

[8] IS 10262: 2009, Indian Standard Recommended Guidelines for Concrete Mix Design. Bureau of Indian Standards.

[9] Bhangale P.P. and P.M. Nemade, “ Study of pond ash (BTPS) use as a fine aggregate in cement concrete,

”International Journal of Latest Trends in Engineering and Technology (IJLTET) volume 2, March 2013, pp292- 297.

[10] Arunkumar Dwivedi, Dhiraj Kumar S.Lal, “Influence of Addition of Pond Ash as Partial Replacement with Sand and Cement on the properties of Mortar”

International Journal of Innovative Technology, Volume2, Issue4, March 2013.

[11] A.G. Patil, L. Gupta,(Aug2015), “Studies on Strength Characteristics of Pond ash replaced Fibre Reinforced Pavement Quality Concrete” International Journal of Engineering research and Applications, Volume05,Issue-8, pp.34-41.

About Authors

Chhajed Samaksh R. He received his BE from. S.N.D.

College of Engineering and currently perusing. ME from Civil Engineering Department, S.N.D. College of Engineering and RC Yeola, Nashik, India.. His main area of interest is Overview Of Partial Replacement Of Concrete With Partial Replacement Of Fine Aggregate By Pond Ash.

Dr. R.S. Kale, He Received his M.Tech and Ph.D from IIT Pawai Mumbai and K.K.W College of Engineering Nashik, and currently working as Associate Professor Civil Engineering Department, S.N.D. College of Engineering And RC Yeola.

0 1 2 3 4 5 6 7

28 days Flexural strength (N/mm2)

No . of Days

Mix- 1 Mix- 2 Mix- 3 Mix- 4