A PROJECT REPORT ON EFFECT OF SIZE OF AGGREGATE ON SELF COMPACTING CONCRETE OF M70 GRADE. SUBMITTED BY AMAN VERMA, ROLL NO. 2023013304 BRANCH- STRUCTURAL ENGINEERING (38D SEM) DEPARTMENT OF CIVIL ENGINEERING MADAN MOHAN MALVIVA UNIVERSITY OF TECHNOLOGY, GORAKHPUR, 1IPageDECLARATION BY THE CANDIDATE | AMAN VERMA hereby declare that the project report entitled “STUDY OF EFFECT OF SIZE OF AGGREGATE ON SELF COMPACTING CONCRETE OF M70 GRADE’, Under the guidance of DRAK.MISHRA(HCED), Professor, Civil Engineering Department is submitted in the fulfilment of the requirements for the MINOR-PROJECT. This is a bonafide work carried out by meand the results embodied in this project report have not been reproduced/copied from any source. ‘The results embodied in this project report have not been submitted to any other university or institution for the award of any other degree or diploma. Date: Place: Givil Engineering Department MMMUT GORAKHPUR Contact No: Contact Address: ACKNOWLEDGEMENT 21PaFinally we thank all the unmentioned names and invisible hands who helped us in bringing this MAIN PROJECT Report to the present form, Chapter-1 Introduction 10 GeneralLd 12 124 12.2 123 124 125 126 13 14 Ls 15.1 Chapter -2 Chapter -3 3.0 Bl 32 33 4iPage ‘Mechanism for Achieving Self-Compact ability Constituents of SCC Coarse Aggregate Fine Aggregate Cement Water Mineral Admixtures Chemical Admixtures Worldwide utility of Self Compacting Concrete Development of Self Compacting Concrete in India Mechanical Properties of Self Compacting Concrete Fresh and hardened properties of Self Compacting Concrete Objectives and Scope of Work Experimental Program Fly Ash Super Plisticizer Viscosity Modifying Agent Mix Proportioning Batching and mixing of Self Compacting Concrete a aw u 1B “ 16 16 a 2 2 23 23 28 3134 34.1 34.2 343 34.3.1 34.3.2 3433 3434 343.5 35 36 37 B71 37.2 373 Chapter - 4 41 42 43 43.1 43.2 43.3 Chapter - 5 50 SiPage Fresh Properties of Self Compacting Concrete Requirements of Self Compacting Concrete Workability criteria for the fresh Self Compacting Concrete ‘Test Methods Slump Flow test and Tsp em test L- Box Test. ‘Y- Funnel test and V- Funnel test at Ts minutes Je ring test U- Box test Size of Test Specimen used Curing of test specimens ‘Tests on hardened concrete Compressive Strength Flexural Strength Split Tensile Strength Experimental results Mix proportions for Self Compacting Concrete Fresh Properties of Self Compacting Concrete Mechanical Properties of Self Compacting Concrete with, different sizes of aggregates Compressive Strength Split Tensile Strength Flexural Strength Interpretation and Discussion of Test results General 31 31 39 38. 4 43 a 55 555. 5.2 53 53.1 53.2 53.3 Chapter - 6 60 Chapter -7 Table No. Discussion on Mix proportions adopted for Self Compacting Concrete Effect of size of aggregate on Fresh properties of Self ‘Compacting Concrete Effect of size of aggregate on Mechanical properties of Self Compacting Conerete Compressive Strength Split Tensile Strength Flexural Strength Self Compacting Concrete Mix Design procedure Development of a rational Mix design procedure ‘Conclusions References List of referred Standard Code Books List of referred text books ‘Mix Design of Self Compacting Concrete for M70 grade List of Tables ‘Name of the Table Page.No 3.1. Physical properties of Ordinary Portland Cement 3.2 Physical properties of Coarse and Fine aggregate 22 24 55 56 1 m 6 133 34 35 3.6 37 38 3.9 3.10 4a 42 43 44 45 61 62 63 64 Figno 1 24 Bu TiPage ‘Typical Oxide Composition of Indian fly ash (Chemical requirements of fly ash Physical requirements of fly ash Details of Super Plasticizer Details of Viscosity Modifying Agent Mix Proportion and Quantities of M70 grade of SCC List of test methods for workability properties of SCC Acceptance criteria for Self-compacting Concrete Parameters of M70 grade SCC mix proportions Fresh properties of M 70 grade SCC Compressive strength of M 70 grade SCC Split tensile strength of M 70 grade SCC Flexural strength of M 70 grade SCC Details of packing factor and strengths Fine aggregate to total aggregate ratio Cement content for three grades of concrete ‘water-cement ratio for M70 grade of concrete List of Figure ‘SEM Micrograph of Fly ash particles ‘Schematic representation of Flow of work ‘Slump flow test and T50 cm test procedure (SCC mixes) 27 28 29 30 33 34 52 53 53 54 54 o7 6 69 Page no Ww 19 3732 33 34 35 36 37 39 3.10 41 42 43 44 45 46 47 48 49 4.10 4.1 4.12 61 8IPage LBox test Apparatus ‘V funnel test Apparatus Ubox test Apparatus Specimen casting Specimen Curing Compressive strength test setup ‘Schematic diagram for Flexure test setup Flexure strength test Split tensile strength test 3 days Compressive strength with various sizes of Aggregates 7 days Compressive strength with various sizes of Aggregates 28 days Compressive strength with various sizes of Agaregates 3 days Split Tensile strength with various sizes of Aggregates 7 days Split Tensile strength with various sizes of Aggregates 28 days Split Tensile strength with various sizes of Aggregates 3 days Flexural strength with various sizes of Aggregates, 7 days Flexural strength with various sizes of Aggregates 28 days Flexural strength with various sizes of Aggregates Bar Diagram of Compressive Strength with various sizes of, Aggregates Bar Diagram of Flexural Strength with various sizes of Aggregates Bar Diagram of Split Tensile Strength with various sizes of Aggregates Flow chast of SCC mix design 39 41 43 45 50 SI 37 58 58 59Abstract Concrete is a versatile widely used construction material. Ever since conerete kas been accepted as a material for construction, researchers have beea trying to improve its quality and enhance its performance. Recent changes in construction industry demand improved durability of structures. There is a methodological shift in the concrete design from a strength based concept to a performance based design. At present there is a large emphasis on performance aspect of concrete. One such thought has lead to the development of Self Compacting Concrete (SCC). It is considered ss “the most revolutionary developmest in ‘concrete construction”. SCC is a new kind of High Performance Concrete (HPC) with ‘excellent deformability and segregation resistance. It can flow through and Gill the gaps of reinforcement and corners of moulds without any nesd for vibration and compaction during the placing process. 91Page‘The guiding principle behind self-compaction is that “the sedimentation velocity of a particle is inversely proportional tothe viscosity of the floating medium in which the particle exists”. ‘The other features of mix propertion of SCC include low water to cementitious material ratio, high volume of powder, high paste to aggregate ratio and less amount of coarse aggregate. (One of the popularly employed techniques to produce Self Compacting Conerete is to use fine materials like Fly Ash, GGBES etc; in concrete, besides cement, the idea being to increase powder content or fines in concrete. ‘The original contribution in the field of SCC is attributed to the pioneering work of Nan Su et al: who have developed a simple mix design methodology for Self Compacting Concrete. In this method, the amount of aggregate required is determined first, based an Packing Factor (PF). This will ensure that the concrete obtained has good flowability. self compacting ability and other desired SCC properties. The European Federation of Producers and Applicators of Specialist Products for Structures (EFNARC) [2005] have also laid down certain guidelines {or fresh properties of SCC. ‘The present investigation is aimed at developing high strength Self Compacting Concrete of M70 Grade. The parameters of study include grade of concrete and effect of size of aggregate. ‘The existing Nan Su [2001] method of mix design was based on packing factor for a particular grade of concrete, obtained on the basis of experimental investigation. SCC characteristics such as flowabiity, passing ability and segregation resistance have been ‘verified using slump flow, L box and V funnel tests Chapter -1 INTRODUCTION 1.0 General ‘The versatility and the application of concrete in the construction industry need not be emphasized. Research on normal and high strength concrete has been on the agenda for more than two decades. As per IS: 456— wiPaceul 2000[Code of Practice for Plain and Reinforced Concrete], concretes ranging 25 - 55 MPa are called standard concretes while those above 55 MPa can be termed as high strength concrete. Concretes above 120/150 MPa are called ultra high strength concrete. High strength concrete has numerous applications world wide in tall buildings, bridges with long span and buildings in aggressive environments. Building elements made of high strength concrete are usually densely reinforced. This congestion of reinforcement leads to serious problems while concreting. Densely reinforced. concrete problems can be solved by using concrete that can be easily placed and spread in between the congested reinforced concrete elements. A highly homogeneous, well spread and dense concrete can be ensured using such a type of concrete. Self-compacting concrete (SCC) is a concrete, which flows and compacts only under gravity. It fills the mould completely without any defects. Usually self-compacting concretes have compressive strengths in the range of 60-100 N/mm?. However, lower grades can also be obtained and used depending on the requirement. SCC was originally developed at the University of Tokyo in Japan with the help of leading concrete contractors during 1980's to be mainly used for highly congested reinforced structures in seismic regions. As durability of concrete structures was an important issue in Japan, an adequate compaction by skilled labors was required to obtain durable concrete structures. This requirement led to the development of SCC. The development of SCC was first reported in 1989. UiPaSCC is 2 new kind of High Performance Concrete (HPC) which has an excellent deformability and segregation resistance. By name it can be defined as a concrete, which can flow through and fill the gaps of reinforcement and. corners of the moulds without any need for external vibration. SCC compacts itself due to its self weight and de-aerates almost completely while flowing in the formwork. SCC can also be used in situations where it is difficult or impossible to use mechanical compaction for fresh concrete, such as underwater concreting, cast in-situ pile foundations, machine bases and columns or walls with congested reinforcement. The high flowability of SCC makes it possible to fill the formwork without vibration. Since its inception, it has been widely used in large construction works or projects in Japan. Recently, this concrete has gained wide use for different applications and structural configurations across the world. High strength concrete can be produced with normal concrete. But these concretes cannot flow freely by themselves, to pack every corner of moulds and all gaps of reinforcement. High strength concrete based elements require thorough compaction and vibration in the construction. process, SCC has more favourable characteristics such as high fluidity, good segregation resistance and distinctive self-compacting ability with out any need for external or internal vibration during the placing process. It can be compacted into every corner of formwork purely by means of its own weight without any segregation. Hence, it reduces the risk of honey combing of concrete. Development of SCC is a very desirable achievement in the construction industry for overcoming the problems associated with cast-in place concrete. It is not affected by the skill of workers, shape and amount 121Pa3 of reinforcing bar arrangement of a structure. Due to its high fuidity and resisting power to segregation, it can be pumped over longer distances. It extends the possibility of use of various by products in its manufacturing. ‘The use of SCC not only shortens the construction period but also ensures quality and durability of concrete. It replaces manual compaction of fresh. concrete with a modern semi-automatic placing technology. Some of the advantages of Self Compacting Concrete are as follows: 1. Less noise from vibrators and reduced danger from Hand Arm Vibration ‘Syndrome (HAVS). 2. Safe working environment. 3. Speed of placement, resulting in increased production efficiency. 4. Ease of placement, requiring fewer workers for a particular pour. 5. Better assurances of adequate uniform consolidation. 6. Reduced wear and tear on forms from vibrator. 7. Reduced wear on mixers due to reduced shearing action. 8, Improved surface quality and fewer bug holes, requiring fewer patching. 9. Improved durability. 10. Increased bond strength. 11. Reduced energy consumption from vibration equipment. 12. Best suited where reinforcement congestion is a problem. 131Pa‘The functional requirements of a fresh SCC are different from those of a vibrated fresh Normal Concrete (NC). Filling of formwork with a liquid suspension requires workability performance like filling ability, passing ability and resistance against segregation. Filling ability of concrete is the ability of concrete to flow freely under its own weight, both horizontally and vertically upwards if necessary, and to completely fill the formwork of any dimension and shape without leaving voids. Passing ability is the ability of conerete to pass through obstacles such as narrow sections of the form work, closely spaced reinforcement etc. without blocking caused by interlocking of aggregate particles. Resistance to segregation is maintaining homogeneity throughout mixing, transportation and casting The dynamic stability refers to the resistance to segregation during placement. The static stability refers to the resistance to bleeding, segregation and surface settlement after casting. 1,1Mechanism for Achieving Self-Compactability Simply increasing the water content in a mix to achieve a flowable concrete like SCC is obviously not a viable option. Instead, the challenge is to increase the flowability of the particle suspension and at the same time avoid segregation of the phases. The main mechanism controlling the balance between higher flowability and stability are related to surface chemistry. The development of SCC has thus been strongly dependent on. surface active admixtures as well as on the increased specific surface area obtained through the used fillers. iat‘The method for achieving self-compactability involves not only high deformability of paste or mortar, but also resistance to segregation between coarse aggregate and mortar when the concrete flows through the confined zone of reinforcing bars. Hajime Okamura et al.,[2003] and Ozawa K et al., [1989] have employed the following methods to achieve self-compactability. (a) Limited aggregate content (b) Low water-powder ratio (c) Use of Super Plasticizer (SP) ‘The frequency of collision and contact between aggregate particles increases as the relative distance between the particles decreases and the internal stress increases when concrete is deformed, particularly near obstacles. It has been revealed that the energy required for flowing is consumed by the increased internal stresses, resulting in blockage of aggregate particles. Limiting the coarse aggregate content, whose energy consumption is particularly intense, to a level lower than normal proportions is effective in avoiding this kind of blockage. Highly viscous paste is also required to avoid the blockage of coarse aggregate when conerete flows through obstacles. When concrete is deformed, the paste with high viscosity also prevents locelized increase in the internal stress, due to the approach of coarse aggregate particles. High deformability can be achieved only by the employment of a superplasticizer, keeping the water-powder ratio at a very lower level. Is!1.2 Constituents of SCC 1.2.1 Coarse aggregate: ‘The coarse aggregate chosen for Self Compacting Concrete should be well graded and smaller in terms of the maximum size than that used for conventionally vibrated concrete (NC). For typical conventional concrete (NC) the coarse aggregate size may be 20 mm and even more in general. The rounded aggregates and smaller size of aggregate particles improves the Flowability, deformability and segregate resistance of SCC. The gradation is an important factor in choosing a coarse aggregate, where, highly congested reinforcement patterns are used and where, very smalll dimensional elements, are to be produced. In case of conventional concrete (NC), the size of the coarse aggregate depends upon the type of the construction. Like in case of conventional concrete (NC), size of aggregate has a key note to play in SCC designs also. Hence, studies are needed to assess the maximum size of aggregate for a particular grade of concrete. Usually, the maximum size of the coarse aggregate used in production of SCC, ranges approximately between 10mm and 20mm. 1.2.2 Fine Aggregate: All normal river sands are suitable for SCC. Poth crushed and rounded sands can be used. Siliceous and calcareous sands can be used for production of SCC. The amount of fines less than 0.125mm is to be considered as powder which is very important for the rheology of SCC . A minimum amount of fines must be maintained to avoid segregation. The amount of fines has a very significant effect on SCC mix proportions. Fine sand requires more water and Super Plasticizer (SP), but less filler than 16lPage7 coarse sand. The SP dosage, water content and cement/filler content could be adjusted by treating the fines (>150 um) in sand as part of the filler. 1.2.3 Cement: All types of cements conforming to Bureau of Indian standards are suitable as per Indian conditions. Selection of the type of the cement is made depending on the over all requirements of SCC such as strength, durability ete. The cement content can be 350 - 450 kg/m. The usage of cement more than 500 kg/m? may increase the shrinkage in the hardened state of concrete, where as, the quantity less than 350 kg/m may decrease the durability of SCC. Hence, cement content shall be judged properly. Less than 350 kg/m* may also be used with the inclusion of other fine fillers such. as fly ash, Ground Granulated Blast furnace Slag (GGBS) and rice husk ash. 1.2.4 Water: Fotable water shall be used for the production of SCC. In case of conventional concretes (NC), the water is proportionate only with the cement content, It is called as the water-cement ratio. This influences the mix and thereby workability. But, in the case of SCC, instead of water-cement ratio the term water binder-ratio will be used. This means the content of water mixed in the SCC is proportionate to the total binders such as cement, fly ash ete, 1.2.5 Mineral admixtures: Mineral admixtures are added to concrete as a part of the cementitious material. They may be used as an addition to or as a part replacement of Portland cement in concrete. This depends on the properties of materials and the desired effect of concrete. Optimum amount of mineral ITIPage18 admixtures are used to improve specific concrete properties euch as workability and strength. Self Compacting Concrete is now considered as a high performance concrete, due to its quality, homogeneity in fresh state, improved durability, faster construction and achieving higher strength. To get better strength properties and good performance of SCC, it requires high quality of cementitious material, mineral admixtures like fly ash, silica fume, GGBFS, limestone powder. To keep the cement quantity at reasonable level, pozzolanic additives are often used. Pozzolonas are also used to produce high performance concrete in terms of strength, workability and durability. This can also be cost effective, ‘The general advantages of mineral admixture additives are: 1. It increases the hydration process and reduces the porosity of concrete. 2. It fills and closes the pores or adjusts the type of pore structure. 3. It increases hydration products in addition to the filling effect of micro ageregate 4. It adjusts the grading of the components to achieve an optimum, compact. 5. It can adjust the cohesiveness and reduce the heat of hydration and reaction rate. 6. It can improve the workability. ise19 7. It can improve the durability and resistance to chemical attack and thus reduce micro cracks in the transition zones. In this study, only fly ash is used as the mineral admixture and an attempt is made to maximize the fly ash content in Self Compacting Concrete. a. Fly Ash: Fly ash or pulverized fuel-ash is a residue from the combustion of pulverized coal collected by mechanical separators, from the fuel gases of thermal plants. The composition of fly ash varies with type of fuel burnt, load on the boiler and type of separation. Fly ash material solidifies while suspended in the exhaust gasses and is collected by electrostatic precipitators or filter bags. Fly Ash consists mostly of silicon dioxide (SiO;), aluminium oxide (AlOs) and iron oxide (FesOs), and is hence a suitable source of aluminum and silicon for geopolymers. They are also pozzolanic in nature and react with calcium hydroxide and alkali to form Calcium Silicate Hydrates (C - S-H). ‘The average particle size of fly ash is about 20 microns, which is similar to the average particle size of Portland cement. Particles below 10 microns provide the early strength in concrete, while particles ite20 between 10 and 45 microns react more slowly. Fig.1.1 shows the SEM micrograph of fly ash particles. The specific gravity of fly ash particles ranges between 2.0 to 2.4 depending on the source of coal. The fineness of fly ash is in the range of 250 - 600 m2/kg. Fig 1.1 SEM Micrograph of fly ash particles 1.2.6 Chemical admixtures: Chemical admixtures are used in Self Compacting Concrete as ingredients which can be added to the concrete mixture immediately before or during mixing. The use of chemical admixtures such as water reducers, retarders, high-range water reducers or Super Plasticizers (SP), and Viscosity Modifying Admixtures (VMA) is necessary in order to improve the fundamental characteristics of fresh and hardened concrete. They help in the efficient use of large amount of cementitious material in high strength and self-compacting concretes so as to obtain the lowest water to cementing materiale ratio. a. Super Plasticizer:Generally, in order to increase the workability, the water content is to be increased provided a corresponding quantity of cement is also added to keep the water cement ratio constant, so that the strength remains the same. Portland cement, being in fine state, has a tendency to flocculate in wet concrete. This flocculation entraps certain amount of water used in the mix and there by all the water is not freely available to increase the fluidity of mix. On the other hand, to avoid the use of excess quantity of water and cement, SP is used to increase the fluidity of the mix and improve the workability of concrete. 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 over come the attractive forces. This repulsive force is called zeta potential which depends on the base, solid contents and quality of super plasticizer used. Then, the cement particles are deflocculated and the water trapped inside the flocks gets released and the water is available to fluidify the mix. The job of super plasticizer is to impart a high degree of flowability and deformability which are essential for the development of SCC. However, the higher dosages of SP can lead to a high degree of segregation. Superplasticizer is a chemical compound used to increase the workability without adding more water. It has the property of spreading the given water in the concrete through out the concrete mix resulting in a uniform mix. Thus, superplasticizer is essential for the creation of SCC. b. Viscosity Modifying Agent: ‘The use of Viscosity Modilying Agent (VMA) gives higher possibilities of controlling segregation in SCC when the amount of powder is limited. This admixture helps to maintain very good homogeneity and also reduces the 21Page2 tendency to segregate. The VMA is incorporated to enhance the yield value and viscosity of fluid mixture. World-wide utility of Self Compacting Concrete: Self compacting concrete has already been used in several countries. In Japan, SCC is used in major construction projects in the late "00s. Today, SCC is treated as a special concrete and efforts are made to integrate in the day-to-day concrete industry production. Currently, the percentage of self-compacting concrete in the annual production of Ready- Mixed Concrete (RMC), as well as Precast Conerete (PC), in Japan i s around 1.2% and 0.5% of concrete products. In United States, the precast industry is also implementing SCC technology through the Precast/Prestressed Concrete Institute (PCI) which has done some research on the use of SCC in precast/prestressed concretes. There is a wide application of SCC in Precast/Prestressed industries in United States. There is an estimated 8000 m3 of SCC used just in the first quarter of 2003, almost 1% of the annual ready-mix conerete. Several state departments of transportation in the United States are involved in the study of SCC. Due to a high level of interest from the construction industry, as well as manufacturers of this new concrete, use of SCC is growing at a tremendous rate in the United States and across the world. Even though material constituents of SCC are same as that of conventional concrete [NC] including the whole process, from mix design to 21