Chapter 9

EXPERIMENTAL PROCEDURE AND TEST RESULTS

9.1GENERAL
In this project an attempt is made to find out the effect of replacement of natural aggregates by
recycled aggregate in different percentages, on the strength and workability characteristics of
concrete. In addition to this, the effect of replacement of cement by supplementary cementations
materials like fly ash and silica fume in recycled aggregate concrete is also investigated.

9.2 MATERIALS USED

In the experimentation 43 grade ordinary Portland cement was used. Locally available
sand and aggregates were used. The sand was confirming to zone 11 and its specific gravity was
found to be 2.91.The natural coarse aggregates used in the experimentation were of 12mm and
down size aggregates and its specific gravity was 2.83.The recycled aggregates were obtained by
crushing the old concrete specimens. After crushing, the recycled aggregates were sieved and
12mm and down size aggregates were used.
The fly ash used in the experimentation was obtained from thermal power plant; Raichur.
The chemical compositions of fly ash given by the supplier are shown in table9.1.
Table 9.1: Chemical composition of fly ash

Oxides Mass Percentage

SiO2 50
Al2O3 28
Fe2O3 9
CaO 3
MgO 1
SO3 1
Others 8
The silica fume used in the experimentation was obtained from ELKEM laboratories;
Mumbai. The chemical compositions of fly ash given by the supplier are shown in table9.1.

Table 9.2.: Chemical composition of silica fume

 Chemical composition Mass Percentage
Silica (SiO2) 89
Alumina(Al2O3 ) 0.5
Iron Oxide(Fe2O3 ) 2.5
Alkalies as(Na2O+K2O) 1.2
Calcium Oxide(CaO ) 0.5
Magnesium oxide(MgO ) 0.6

9.3 CASTING PROCEDURE AND TESTING

The cement, sand and natural aggregates were dry mixed, in the proportion of
1:1.67:3.290(which corresponds to M20 grade of concrete).Before adding the natural aggregates
they are replaced by recycled aggregates in different percentages like 0%, 20%, 30%40%, 60%,
80%, 100% as the case may be.Also the cement was replaced by fly ash in by 25%.Also in an
another set the cement was replaced by silica fume by10%. This dry mix is homogeneously
mixed. The required amount of water (W/C ratio=0.44) was added to this dry mix. The recycled
aggregates wre subjected to pre-wettimg for 10 to 15minutes, with water quantity equal yo the
absorption of the recycled aggregates and homogeneously mixed. This homogeneous concrete
mix was placed in the moulds, which were kept on the vibrating table. The concrete was
compacted both through table vibrator as well as through hand compaction. The specimens were
finished smooth and taken out of the vibrating table. The specimens were covered with wet
gunny bags and after 24 hours they were demoulded.After demoulding the specimens were
transferred to the curing tank where in they were allowed to cure for 28 days. After 28 days of
curing they were weighed for their density and tested for their respective strengths.

Tests conducted:
On Fresh concrete: (i) Determination of concrete density

(ii) Workability test: Slump test was conducted for every varition of
recycled aggregate.

On Hardened concrete: (i) Compressive Test

(ii) Tensile Test
(iii) Flexural strength
(iv) Saturated water absorption.
Compressive Test: To find out the compressive strength the cubes of dimensions 150 x 150 x
150mm were caste and tested on compressive testing machine of capacity 200KN as per 516 :
1959

Tensile Test : To find out the tensile strength cylinders of dimensions 150mm diameter and
300mm length were casted and they were tested in compressive testing machine by keeping them
longitudinally as per 5816 : 1999 This test is called indirect tensile test or split cylindrical tension
test. The split cylindrical tensile stress is obtained by the equation.

f=2P/∏dl

Where,

P=failure load

d=diameter of the cylindrical specimen (150mm)

l=length of the cylindrical specimen (300mm)

Flexural strength: To find out the flexural strength, the beams of dimensions 100X100X500mm
were casted. Two point loading was adopted on an effective span of 400mm, while testing the
beam specimens as per 516 : 1959. The flexural strength can be calculated by the equation….

f=PL/bd2

Where,

P= failure load

L=effective span (400mm)

b=breadth of the beam=100mm

d=depth of the beam=100mm

After 28 days of curing the specimens were tested for their respective strength and the values are
tabulated.
9.4 TEST RESULTS
9.4.1.1 Workability test results

The following table 9.3 gives the workability values in terms of slump for concrete when
natural aggregates are replaced by recycled aggregates in different percentages like 0%,
20%,40%,60%,80% & 100% and cement is replaced by 10% fly ash.

Table 9.3: Overall results of workability

Percentage replacement Slump

of natural agg by
recycled agg
0%(Ref mix) 49
20% 37
30% 33
40% 28
60% 22
80% 16
100% 11
9.4.1.2 COMPRESSIVE STRENGTH TEST RESULTS

The following tables give the compressive strength test results on concrete when natural
aggregates are replaced by recycled aggregates in different percentages and when cement is
replaced by fly ash by 25%.

Table 9.4: Compressive strength of concrete cubes when natural aggregates are replaced
by recycled aggregates by 0% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3 density load strength compressive

(N) ) (kN/m3) (kN) (MPa) strength

(MPa)
92.02
A1 27.26 2 630 28.00 26.

A2 90.84 26.92 6.70 610 27.11 89

A3 87.51 25.93 575 25.56

Table 9.5: Compressive strength of concrete when natural aggregates are replaced by
recycled aggregates by 20% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3) density load strength compressive

(N) (kN/m3) (kN) (MPa) strength

(MPa)
B1 83.19 24.65 530 23.56 24.4

B2 87.51 25.93 24.98 550 24.44 4

B3 82.21 24.36 570 25.33

Table 9.6: Compressive strength of concrete when natural aggregates are replaced by
recycled aggregates by 30% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3) density load strength compressive

(N) (kN/m3) (kN) (MPa) strength

(MPa)
C1 83.58 24.76 2 560 24.89 24.

C2 84.37 25.00 4.76 550 24.44 30

C3 82.80 24.53 530 23.56

Table 9.7: Compressive strength of concrete when natural aggregates are replaced by
recycled aggregates by 40% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3) density load strength compressive

(N) (kN/m3) (kN) (MPa) strength

(MPa)
D1 83.58 24.76 2 530 23.56 24
83.97 4.92 .00
D2 24.88 520 23.11
84.76
D3 25.11 570 25.33

Table 9.8: Compressive strength of concrete when natural aggregates are replaced by
recycled aggregates by 60% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3) density load strength compressive

(N) (kN/m3) (kN) (MPa) strength

(MPa)
E1 89.47 26.51 530 23.56

E2 87.90 26.04 25.68 540 24.00 23.26

E3 82.60 24.47 500 22.22
Table 9.9: Compressive strength of concrete when natural aggregates are replaced by
recycled aggregates by 80% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3) density load strength compressive

(N) (kN/m3) (kN) (MPa) strength

(MPa)
F1 90.64 26.86 2 540 24.00 22.

F2 87.90 26.04 5.79 480 21.33 96

F3 82.60 24.47 530 23.56

Table 9.10: Compressive strength of concrete when natural aggregates are replaced by
recycled aggregates by 100% & cement is replaced by 25% fly ash.

Identification Weight Density Average Failure Compressive Average

of cube (kN/m3) density load strength compressive

(N) (kN/m3) (kN) (MPa) strength

(MPa)
G1 81.62 24.18 530 23.56
G2 80.83 23.95 500 22.22
24.30 22.37
G3 83.58 24.76 480 21.33

Overall results of compressive strength

Table 9.11 gives the overall results compressive strength of concrete when natural aggregates
are replaced by recycled aggregates and when cement is replaced by 25% fly ash. It also gives
the percentage increase or decrease of compressive strength with respect to reference mix.
Table 9.11: Overall results of compressive strength

Percentage replacement Compressive Percentage increase or decrease

of NA by RA strength (MPa) of compressive strength w.r.t.
reference mix
0%(Ref mix) 26.89 0.00
20% 24.44 -9.11
30% 24.30 -9.63
40% 24.00 -10.75
60% 23.26 -13.50
80% 22.97 -14.62
100% 22.37 -16.81

The above results can be depicted in the form of graph as shown in fig 9.1

Fig 9.1 Variation of compressive strength of concrete when natural aggregates are replaced
by recycled aggregates in different percentages and cement is replaced by 25% fly ash.

9.4.1.3 TENSILE STRENGTH TEST RESULTS

The following tables give the tensile strength test results on concrete when natural aggregates are
replaced by recycled aggregates in different percentages and when cement is replaced by 25% fly
ash.

Table 9.12: Tensile strength of RAC when natural aggregates are replaced by recycled
aggregates by 0% & cement is replaced by25% fly ash.

Identification Failure load Tensile strength Average tensile

F=2P/∏dl strength
(kN)
(MPa) (MPa)
A1 240 3.39
A2 220 3.11
3.21
A3 220 3.11

Table 9.13: Tensile strength of RAC concrete when natural are replaced by recycled
aggregates by 20% & cement is replaced by 25% fly ash.

Identification Failure load Tensile strength Average tensile

F=2P/∏dl strength
(kN)
(MPa) (MPa)
B1 200 2.83
B2 200 2.83
2.88
B3 210 2.97

Table 9.14: Tensile strength of RAC concrete when natural are replaced by recycled
aggregates by 30% & cement is replaced by 25% fly ash.

Identification Failure load Tensile strength Average tensile

F=2P/∏dl strength
(kN)
 (MPa) (MPa)
C1 190 2.69
C2 210 2.97
2.78
C3 190 2.69

Table 9.15: Tensile strength of RAC concrete when natural are replaced by recycled
aggregates by 40% & cement is replaced by 25% fly ash.

Identification Failure load Tensile strength Average tensile

F=2P/∏dl strength
(kN)
(MPa) (MPa)
D1 200 2.83
D2 180 2.55
2.78
D3 210 2.97

Table 9.16: Tensile strength of RAC concrete when natural are replaced by recycled
aggregates by 60% & cement is replaced by 25% fly ash.

Identification Failure load1 Tensile strength Average tensile

F=2P/∏dl strength
(kN)
(MPa) (MPa)
E1 180 2.55
E2 200 2.83
2.69
E3 190 2.69

Table 9.17: Tensile strength of RAC concrete when natural are replaced by recycled
aggregates by 80% & cement is replaced by 25% fly ash.

Identification Failure load Tensile strength Average tensile

F=2P/∏dl strength
(kN)
(MPa) (MPa)
180 2.55
F1
 F2 190 2.69
2.59
F3 180 2.55

Table 9.18: Tensile strength of RAC concrete when natural are replaced by recycled
aggregates by 100% & cement is replaced by 25% fly ash.

Identification Failure load Tensile strength Average tensile

F=2P/∏dl strength
(kN)
(MPa) (MPa)
G1 170 2.40
G2 180 2.55
2.55
G3 190 2.69

Overall results of tensile strength

Table 9.19 Gives the overall results of concrete when natural aggregates are replaced by
recycled aggregates and when cement is replaced by 25% fly ash. It also gives the percentage
increase or decrease of tensile strength with respect to reference mix.

Table 9.19: Overall results of tensile strength

Percentage replacement of Tensile strength Percentage increase or

cement by fly ash (MPa) decrease of tensile strength
w.r.t. reference mix
0%(Ref mix) 3.21 0.00
20% 2.88 -10.28
 30% 2.78 -13.40
40% 2.78 -13.40
60% 2.69 -16.20
80% 2.59 -19.31
100% 2.55 -20.56
The above results can be depicted in the form of graph as shown in fig 9.2

Fig 9.2 Variation of tensile strength of concrete when natural aggregates are replaced by
recycled aggregates in different percentages and cement is replaced by 25% fly ash.