A MAJOR PROJECT

On

EFFECTS OF STONE DUST ON M20 GRADE CONCRETE

A Project report submitted in partial fulfilment of the requirements for the award of the
degree of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

Submitted to

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY

Submitted by

SHAIK NAGUL MEERA 177Y1A0118

Under the esteemed guidance of
Ms. M. NANDITHA
Associate Professor

DEPARTMENT OF CIVIL ENGINEERING

2020 - 2021

i
 DEPARTMENT OF CIVIL ENGINEERING
CERTIFICATE

This is to certify that the project entitled ‘EFFECTS OF STONE DUST ON M20
GRADE CONCRETE’ being submitted by Shaik Nagul Meera (177Y1A0118) in
partial fulfilment for the award of the Degree of Bachelor of Technology in Civil
Engineering of MARRI LAXMAN REDDY INSTITUTE OF TECHNOLOGY AND
MANAGEMENT, Dundigal, Hyderabad during the academic year (2020-21).

Project Guide Head of the Department

Ms. M. NANDITHA, M.Tech (PhD) Mr K. MURALI, M.E,(Ph.D)
Associate Professor

External Examiner Principal

Dr. K. VENKATESWARA REDDY,
M.Tech., Ph.D., MISTE

ii
 DECLARATION OF CANDIDATE

I hereby declare that the matter embodied in the report of mini project entitled "
EFFECTS OF STONE DUST ON M20 GRADE CONCRETE “is genuine research work
carried out by me under the guidance of Ms.M.NANDITHA, M.Tech(PhD), Associate
Professor, Department of Civil Engineering, Marri Laxman Reddy Institute of
Technology and Management, Dundigal, Hyderabad.

The work embodied in this report is original & has not been submitted to the basis
for the award of degree, diploma, associate ship or fellowship of any other University or
Institution.

SHAIK NAGUL MEERA

iii
 ABSTRACT

Stone dust is a waste material obtained from crusher plants. The concept of replacement of
natural fine aggregate by stone dust which is highlighted in the study could boost the
consumption of stone dust generated from quarries. By replacement of stone dust the
requirement of land fill area can be reduced and can also solve the problem of natural sand
scarcity for future generations. The availability of sand at low cost as a fine aggregate in
concrete is not suitable and that is the reason to search for an alternative material. It even
causes burden to dump the crusher dust at one place which causes environmental pollution.
An experimental program was carried out to study the workability and compressive
strength of concrete made using stone dust as partial replacement of fine aggregate in the
range of 10%-100%.Workability and compressive strength were determined at different
replacement level of fine aggregate and optimum replacement level was determined based
on compressive strength. Results showed that by replacing 60% of fine aggregate with
stone dust concrete of maximum compressive strength can be made as compared to all
other replacementlevels.

iv
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

CERTIFICATE ii
DECLARATION OF CANDITATE iii
ACKNOWLEDGEMENT iv
ABSTRACT v
LIST OF TABLES viii
LIST OF FIGURES xi
LIST OF SYMBOLS AND ABBREVIATIONS x

1. INTRODUCTION 1
2. LITERATURE REVIEW 3
3. METHODOLOGY 3
3.1. General 3
4. EXPERIMENTAL INVESTIGATION 10
4.1. Stone dust 10
4.2. Cement 14
4.3. Aggregate 18
4.4. Water 20
5. TESTS ON CEMENT 22
5.1. Standard consistency of cement 22
5.2. Fineness of cement 23
5.3. Setting time of cement 24
5.4. Specific gravity of cement 25
5.5. Compressive strength of cement 26
6. TESTS ON AGGREGATES 28
6.1. Crushing test 28
6.2. Impact test 29
6.3. Soundness test 29
6.4. Shape test 30
6.5. Specific gravity test 31
6.6. Water absorption test 31
7. MIXTUREP ROPORTIONS 32
7.1. Mix design 32
8. TEST ON CONCRETE 36
8.1. Workability of concrete-slump cone test 36
8.2. Preparation of specimen 37

v
 8.3. Curing 38
8.4. Strength test 40
9. CONCLUSION 46
REFERENCES 47

vi
 LIST OF FIGURES

FIG.NO NAME OF THE FIG PAGE NO.

3.1 STONE DUST 10

4.1 VICAT’S APPARATUS 22

4.2 SIEVE SIZE 90 MICRONS 23

4.3 COMPRESSIVE STRENGTH MACHINE 26

5.1 CRUSHING TEST 28

5.2 IMPACT TEST 29

5.3 FLAKINESS GAUGE 30

5.4 ELONGATION GAUGE 30

7.1 MEASURING OF SLUMP VALUE 36

7.2 FINE AGGREGATE 37

7.3 CEMENT 37

7.4 STONE DUST 38

7.5 COARSE AGGREGATE 38

7.6 CURING OF CUBES 38

7.7 TESTING THE STRENGTH OF CUBE 41

7.8 CUBE COMPACTION 42

vii
 LIST OF TABLES

TABLE NO DETAILS PAGE NO.

3.1 SIEVE ANALYSIS OFSTONEDUST 12

3.2 CHEMICAL COMPOSITION OFSTONEDUST: 13

3.3 CHARACTERISTICSOFCEMENT 16

7.1 COMPRESSIVE STRENGTHOFCONCRETE 43

WITH STONE DUST AT 7 DAYS

7.2 COMPRESSIVE STRENGTHOFCONCRETE 43

WITH STONE DUST AT 14 DAYS

7.3 COMPRESSIVE STRENGTHOFCONCRETE 44

WITH STONE DUST AT 28 DAYS

7.4 AVERAGE COMPRESSIVE STRENGTHOFCONCRETE 44

WITH STONE DUST AT 7, 14 AND 28 DAYS

7.5 VARIATION IN WORKABILITYBY ADDING 47

DIFFERENT %’S OF STONE DUST

8
 LIST OF GRAPHS

GRAPH NO DETAILS PAGE NO.

7.1 COMPRESSIVE STRENGTH OF CONCRETE 45

WITH STONE DUST AT 7 DAYS

7.2 COMPRESSIVE STRENGTH OF CONCRETE 45

WITH STONE DUST AT 14 DAYS

7.3 COMPRESSIVE STRENGTH OF CONCRETE 46

WITH STONE DUST AT 28 DAYS

7.4 AVERAGE COMPRESSIVE STRENGTH OF 46

CONCRETE WITH STONE DUST AT 7, 14 AND

28 DAYS

7.5 VARIATION IN WORKABILITY BY ADDING 47

DIFFERENT %S OF STONE DUST

ix
 CHAPTER 1
INTRODUCTION

In India, river sand is used as fine aggregate in concrete over a period of millions
of years. In general, the demand of river sand is very high in developing countries to
satisfy the rapid infrastructure growth. The demand for river sand in the construction
industry has consequently increased due to the extensive use of concrete resulting in the
reduction of sand sources and increase in pricein this situation developing country like
India facing shortage in good quality of river sand. Concrete is most widely used
construction material. Quarry dust is a byproduct of the crushing process which is a
concentrated material to use as aggregates for concreting purpose, especially as fine
aggregates. In quarrying activities, the rock has been crushed into various sizes; during
the process the dust generated is called quarry dust and it is formed as waste. Soit
becomes as a useless material and also results in air pollution. Therefore, quarry dust
should be used in construction works, which will reduce the cost of construction and the
construction material would be saved and the natural resources can be used properly.
Most of the developing countries are under pressure to replace fine aggregate in concrete
by an alternate material also to some extent or totally without compromising the quality
of concrete. Quarry dust has been used for different activities in the construction industry,
such as building materials, road development materials, aggregates, bricks, and tiles.
Conventionally Concrete is a composite material made of cement, fine aggregate, coarse
aggregate and water. Major components of concrete are aggregates which are usually
available in natural form. Fine Aggregate used in concrete is usually river sand available
locally or at nearby location. Properties of sand affect the durability and performance of
concrete, so fine aggregate is an essential component of cement concrete. Now a day’s
sand is becoming a very costly material, in this situation research began for cheep and
easily available alternative material than river sand. Going for alternative and
supplementary material which can be used as partial or full replacement of conventional
material can play a vital role in conservation of natural resources. Thus Manufactured
sand (Crushed stone dust), as a fine aggregate, is an attractive alternative of river sand for
cement concrete. It is made of fine aggregate produced by crushing and screening or
further processing i.e. washing, grading, classifying of quarried rock, boulders or gravels
from which natural fine aggregate had been removed. The present study has been
attempted to evaluate the characteristics of cement mortar using Crushed stone dust as
fine aggregate and its compare with river sand... The large scale depletion of natural sand
sources create also the environmental problem such as erosion and failure of river banks,
lowering of river beds and saline water intrusion into the land. Thus a investigation is
needed to identify suitable substitute that is eco-friendly, inexpensive and better for
strength and durability performance.In this connection the use of stone dust asfine

1
aggregate with partial or full replacement may be a promising alternative in concrete
making.

The concrete is a composite material which is predominantly used all over

the world. The strength characteristics of concrete depend upon the properties of
constituent material and their combined action. Fine aggregate is one of the important
constituent materials as far as strength characteristics of concrete are concerned. Increase
in demand and decrease in natural sources of fine aggregate for the production of
concrete has resulted in the need to identify news sources of fine aggregate. River and
which is most commonly used as fine aggregate in the production of concrete and mortar
poses the problem of acute shortage in many areas. At same time increasing quantity of
crushed stone dust is available from crusher as waste. The disposal of this dust is serious
environmental problem. If it is possible to use this crushed stone dust in making concrete
and mortar by partial or full replacement of natural river sand then this will not only save
the cost of construction but at the same time will solve the problem of disposal of this
dust. Concrete made with this replacement can attain the same compressive strength
comparable tensile strength and modulus of rupture. For satisfactory utilization of this
alternatives material, the various phases of examination have tobe technical feasibility,
durability of processed concrete and economic feasibility. With the ongoing research
being done to develop appropriate technology and field trail to monitor the performance
and assessment of economic feasibility, the use of alternatives material will become more
viable.

The present research work mainly deals with the influence of different
replacement proportion of sand with quarry dust on the properties of concrete. The
present study is planned to study the effects of quarry dust addition in normal concrete
and to assess the rate of compressive strengthdevelopment.

2
 CHAPTER 2
METHODOLOGY
2.1 GENERAL

This chapter presents the literature reviewed on the effect of using crushed rock
material, quarry dust in place of sand in the preparation of concrete. Some of the
experimental investigations on the strength behaviour of concrete on the use of quarry
dust in the place of natural sand are listed here. In addition to crushed rock material, the
stone dust may be used as an alternative material for fine aggregate sand. To increase the
workability and strength of concrete stone dust may be used. These criteria viewed from
different literature are listed in this chapter.

2.2 LITERATUREREVIEW
Hudson (1997) has conducted experiments to study the performance of concrete
by adding manufacturing sand instead of sand. He prepared trial mixes by using 3 to 20
percentage partial replacement of sand by manufactured sand of minus 75 micron or dust.
The w/c ratio was fixed as 0.7. From the experimental results it was found that there was
remarkable increase in compressive strength in the concrete manufactured with 20
percentage replacement of sand with manufactured sand. This was due to the inclusion of
high percentage of minus 75 micron dust in a suitably graded form with a good particle
shape that allows aggregate packing and results in a denser concrete. The concrete has
lesser permeability and so more durable. This was due to the increased efficiency in void
filling particle force to close capillaries, thereby stopping the passage of liquids
decreasing permeability and durability preventing chemical or liquid ingress into the
concrete. He concluded that the concrete may be used with 20% replacement of sand by
manufactured sand and it was more durable and less permeable.

Mithanthaya and Jeyaprakash Narayan (2002) have conducted experiments to find

the suitability of quarry dust as fine aggregate for plastering and pavement design. Test
was conducted for the mix proportion of cement and quarry dust in 1:3, 1:4, 1:5, 1:6 and
1:7. Tests were conducted and the values obtained were compared with control mortar
containing cement and sand. From test results it was observed that voids present in the
quarry dust mortar was lesser as compared to that of sand, hence high compressive
strength. No cracks were found after 28 days of curing. Cement quarry dust mortar 1:4
mix was used to plaster inside the water tank and found that it was free from leakage.
Based on the test results it was concluded that quarry dust can be utilized for plastering
instead of sand and with proper investigation it may be utilized in the preparation of
concrete also.

3
 Naidu et al (2003) have conducted experiments to investigate the influence of
partial replacement of sand with quarry dust in the compressive strength and pull out
force concrete. Four types of concrete using OPC were prepared using M20 mix with
20% sand replacement in w/c ratios 0.4 and 0.45. The specimens were cast and tested at
the age of 7, 14, 28 and 56 days. From the test results it was observed that for all the ages
at this replacement the compressive strength was lower than normal concrete. It is
concluded that the inclusion of quarry dust in to concrete resulted in a reduction in
compressive strength and this may be compensated by adding admixture. Reduction in
compressive strength might be caused by the particle shape of quarry dust which was
flaky and angular. Aggregates which were flaky tends to be oriented in one plane with
water and air voids forming underneath and thereby result in a reduction in compressive
strength. Insufficient cement paste to coat all the coarse and fine aggregate particles in
quarry dust due to its higher content might have contributed to the reduction in
compressive strength.

Chandrasekhara Reddy (2003) has conducted experiments to study the

performance of concrete using stone dust as a replacement to sand. Sand was replaced by
quarry dust from 0 to 100% at increment of 25%. Compressive strength and tensile
strength tests were conducted using 43 grade OPC in M20 concrete. Compressive
strength was computed at the age of 7 days, 28 days and 60 days. From the test results he
observed that all the mixes except 50% replacement achieved the target strength. The
stone dust decreases workability of concrete due to the larger portions of fine particles.
At 75% of sand replacement, the percentage of increase in compressive and tensile
strength were 40 and 28 compared with reference mix respectively. The unit weight
increases with increase in percentage of replacement of sand. He concluded that sand can
be replaced by stone dust available locally without affecting strength ofconcrete.

Raman et al (2005) have reported in their experimental study about the

investigation of some properties of quarry dust and discuss the suitability of those
properties to enable its usage as a replacement material for sand in concrete. Sand was
replaced by quarry dust in 0%, 20% and 40% .In addition to physical properties the
compressive strength of concrete at the age of 28 days was determined. From the test
results it was observed that partial replacement of sand with quarry dust resulted in a
reduced compressive strength compared with control concrete. It was concluded that
quarry dust can be utilized as a partial replacement material to sand.

ShahulHameed et al (2009) have conducted experiments to study the feasibility of

the usage of quarry rock dust and marble sludge powder as hundred percent substitutes
for natural sand in concrete. Two M20 mixes were prepared using 43 grade OPC, one
with purely river sand and another with quarry dust and marble sludge powder
combination. Tests were conducted on compressive strength, tensile strength, water
absorption, permeability and resistance to sulphate attack. From the test results itwas

4
observed that the water absorption was slightly more. The compressive strength was 14%
more for quarry dust and marble sludge powder combination. It has high workability, less
permeability compared with control concrete. It exhibitexcellent performance due to
efficient micro filling ability and pozzolana activity. It was concluded that quarry dust
and marble sludge powder combination as fine aggregate in concrete wasrecommended.

Lohani et al (2012) have studied the property of the quarry dust and the suitability
to use it as partial replacement material for sand in concrete. Design mix of M20 grade
concrete was used with replacement of 0%, 20%, 30%, 40% and 50% of sand by quarry
dust. They conducted slump test, compaction factor test, compressive strength (cube,
cylindrical sample), split tensile strength, flexural strength, modulus of elasticity and
water absorption test. The durability of concrete was studied by immersing the concrete
cube in 5% solution of MgSO4, 5% solution of NaCl and 2N solution of HCl for 28 and
91 days and results were compared with the standards to achieve the desired parameters.
From the test results it was observed that the concrete does not give adequate workability
with increase of quarry dust. It was due to the extra fineness of quarry dust. Increased
finer requires greater amount of water for the mix ingredients to get closer packing results
in decreased workability. Increase in dust content up to 30% increases compressive
strength of concrete and if the dust content was more than 30% the compressive strength
decreases gradually. But the compressive strength of quarry dust concrete continues to
increase with age for all the percentage of quarry dust contents. Flexural and tensile
strength was maximum at 20% sand replacement. From the above test results it was
concluded that quarry dust can be utilized at 20% replacement.

Joseph et al (2012) have investigated through experiment about flexural and

tensile characteristics of concrete using combination of lateritic sand and quarry dust as
complete replacement for conventional river sand fine aggregate. Specimens were cast in
M20 mix with water cement ratio 0.65 and tested at the age of 28 days. From the test
results it was observed that the tensile and flexural strength were decreased slightly while
sand replaced by quarry dust. It was concluded that the strengths were comparatively
closer with normal concrete and hence concrete with mixtures of lateritic sand and quarry
dust can be used for structural construction below 50% combination.

Priyanka A. Jagadev and DilipK. Kulkarni (2012) have conducted experiments on

concrete to determine mechanical properties using manufactured sand. Specimens were
cast using M20 concrete with water cement ratio 0.45, replacing sand from 0-100% at
increments of 20%. Workability test was carried out in fresh state. Hardened state tests
like compressive, flexural and split tensile strength were conducted at the age of 28 days.
From the test results it was observed that the increase in percentage of replacement of
manufactured sand decreased the workability. The manufactured sand consumes higher
amount of water. The compressive, flexural and split tensile strength of concrete with
60% sand replacement attains higher strength as compared to reference mix. Itwas

5
concluded that manufactured sand has a potential to provide alternative to natural sand
and helps in maintaining the environment as well as economical balance.

Kothai and Malathy (2012) have conducted experiments on self-compacting

concrete with manufactured sand as partial replacement material to natural sand. Using
43 grade OPC, the mixes M20, M25, M30, M35 and M40 were prepared with the sand
replacement from 0-100% at increment of 10%. Tests were conducted to determine
compressive, tensile and flexural strength at the age of 28 days. From the test results it
was found that maximum compressive strength, tensile strength and flexural strength
were obtained at 30% of sand replacement. A relationship between compressive
strength and split tensile strength was obtained as 0.1fck. Similarly 0.657fck, the
relationship between compressive and flexural strength also derived. It was concluded
that partial replacement of natural sand by manufactured sand permits a gain of
compressive, tensile and flexural strength of concrete up to optimum value at 30%
replacement.

Mukesh and charkha (2012) have conducted experiments on concrete to study the
effect of the flexural and tensile strength with partial replacement of ingredients. 40%
sand was replaced by crushed stone dust and cement was replaced by fly ash from 0-40%
at increment of 10%. Flexure and split tensile tests were conducted in M20 mix using
PPC. From the test results it was observed that the maximum flexure and split tensile
strength were obtained 0% fly ash and 40% sand replacement. If the cement was replaced
by fly ash then flexure and split tensile strength were reduced. So the optimum fly ash
content was 0% for PPC cement. It was concluded that crushed stone dust can be partially
used as fine aggregate with conventional river sand in concrete.

Devi and Kannan (2011) have conducted experiments to investigate the use of
crushed rock material as fine aggregate in concrete. Corrosion of steel reinforcement is
one of the main durability problems which the reinforced concrete structures face
worldwide. They studied the strength and corrosion resisting properties of concrete
containing crushed rock material as fine aggregate along with an organic inhibitor. The
inhibitor used was Triethanolamine at 1%, 2%, 3%, and 4% by weight of cement.
Strength tests, water absorption test and the durability tests were conducted and the
results were compared with the natural sand concrete. The resistance to corrosion is
evaluated based on the performance of the concrete for the penetration of chloride ions by
means of impressed current method. From the results obtained it was found that
replacement of sand by crushed rock material increases the strength of the concrete, with
addition of inhibitor. It offers very good resistance against chemical attack and increases
corrosion resistance in addition to the overall properties of concrete. It was concluded
that 100% sand replacement with 2% Triethanolamine can be effectively used in
reinforced concrete structures for delaying corrosion and to increase other strength and
durabilitycharacteristics.

6
 Raman et al (2011) have conducted experimental work to evaluatethe suitability
of quarry dust as a partial substitute for sand in high-strength concrete (HSC) containing
rice husk ash (RHA). Two grades of HSC mixes, to achieve 60 MPa and 70 MPa at 28
days, were designed with and without the incorporation of RHA. Quarry dust was then
used in the mixes containing RHA as a partial substitute for sand, in quantities ranging
from 10% to 40%. The slump of the fresh concrete and the compressive strength
developmentwere monitored up to 28 days. Based on the results obtained, they reported
that the inclusion of quarry dust as a partial replacement material for sand resulted in a
decrease in workability and compressive strength. Mix containing 20% quarry dust and
10% RHA results optimum compressive strength. It was concluded that negative impacts
in workability of fresh concrete due to addition of quarry dust can be compensated by use
of super plasticizer. The findings of the research assert that quarry dust can be used as a
viable replacement material to sand to produce high strength RHA concrete.

Shaikh and Daimi (2011) have conducted experiments to study the strength and
durability performance of concrete made with natural sand and artificial sand with dust.
The durability properties were investigated through microstructure related properties of
concrete such as permeability, water absorption, chloride diffusion and chemical attack.
43 grade OPC was used to prepare concrete mix. The cubes were cast and tested at the
age of 28, 90 and 180 days. From the test results it was found that the mix with artificial
sand with dust as fine aggregate gives higher strength than mix with natural sand. This
was due to sharp edges of particles in artificial sand provides better bond with cement
than the rounded particles of natural sand. The weight loss of artificial sand was same as
natural sand. Low water absorption, moderate chloride permeability was the properties of
both the artificial sand and natural sand used concrete. It was concluded that the full
replacement of natural sand by artificial sand with dust considering the technical,
environmental and commercialfactor.
SachinBalakrishnaKandekar et al (2012) have conducted experiments on concrete
to study the mechanical properties with different fine aggregates. They used grit the
quarry dust, artificial sand and combination of the above two as replacement material to
sand. Mix M20 was adopted to prepare concrete. Hardened state tests like compressive,
flexural and split tensile strength were conducted at the age of 28 days and compared
with control mix. From the test results it was observed that the concrete with grit the
quarry dust as fine aggregate achieved maximum strength. It was concluded that the grit
the quarry dust was more preferable than others.

Joseph et al (2012) have investigated about the structural characteristics of

concrete using various combinations of lateritic sand and quarry dust as complete
replacement for conventional river sand as fine aggregate. Laterite and quarry dust
replaced sand fully in the proportion 0:100, 25:75, 50:50, 75:25 and 100:0. The mixes
M15, M20 and M25 were prepared for workability and cube specimen were cast and
tested forcompressive strength at the age of 3, 7, 14, 21 and 28 days. From the
testresultsit was observed that 25% of laterite with 75% of quarry dust producedgreater
compressive strength. It was concluded that quarry dust may be replaced in place of sand
inconcrete.

7
 Sivakumar et al (2011) have studied the hardened and durable properties of
concrete using quarry dust. Three mixes were used with water cement ratio 0.32 and fine
to coarse aggregate ratio was 0.6, 0.7 and 0.8. The performance of concrete with quarry
dust compared with concrete with sand only. A naphthalene based superplasticizer was
used with dosage not exceeding 1% by weight of cement. Workability, compressive and
tensile tests were conducted using three different binders. From the test results it was
observed that for constant w/c ratio the workability decreases if fine to coarse ratio
increases. This was compensated by addition of superplasticizer. The compressive
strength at 28 days decreased if fine to coarse ratio increases. Maximum compressive and
tensile strength were obtained for fine to coarse ratio 0.6. From the above test resultsit
was concluded that quarry dust may be used as an effective replacement material for
natural riversand.

Devi and Kannan (2011) have conducted experiments to investigate the use of
crushed rock material as fine aggregate in concrete. Corrosion of steel reinforcement is
one of the main durability problems which the reinforced concrete structures face
worldwide. They studied the strength and corrosion resisting properties of concrete
containing crushed rock material as fine aggregate along with an organic inhibitor. The
inhibitor usedwas

Triethanolamine at 1%, 2%, 3%, and 4% by weight of cement. Strength tests,

water absorption test and the durability tests were conducted and the results were
compared with the natural sand concrete. The resistance to corrosion is evaluated based
on the performance of the concrete for the penetration of chloride ions by means of
impressed current method. From the results obtained it was found that replacement of
sand by crushed rock materialincreases the strength of the concrete, with addition of
inhibitor. It offers verygood resistance against chemical attack and increases corrosion
resistance in addition to the overall properties of concrete. It was concluded that 100%
sand replacement with 2% Triethanolamine can be effectively used in reinforced concrete
structures for delaying corrosion and to increase other strength and durability
characteristics.

Rajendra Prasad et al (2011) have conducted experimental worksto study the

effect of crushed rock powder (CRP) as fine aggregate and partialreplacement of cement
with admixtures subjected to different curing methods.Sand was replaced by CRP in 0%,
10%, 20%, 40%, 60%, 80% and 100% andcement replaced by 10% Rice husk ash
(RHA). 53 grade OPC was used toprepare M30 concrete with water cement ratio 0.45.
From the test results itwas observed that 10% RHA with 20% quarry dust replacement
combinationgave better compressive strength. Other than 20% replacement obtained
lessercompressive strength compared with control concrete. This was due to thevoids
present in the concrete mixes with higher amount of CRP. It wasconcluded that quarry
dust can be utilized in concrete replacingsand

Radhikesh Nanda et al (2010) have conducted experiments of cement concrete

paving block replacing sand by stone crusher dust as fine aggregate. Paving block of size
0.25x0.20x0.05 m was cast with mix M20 byweight with water cement ratio 0.6.

8
Compressive, flexural and split tensiletests were conducted by replacing sand by crusher
dust from 0-100% atincrements of 25%. From the test results it was observed that the
compressivestrength was decreased if the addition of crusher dust increases.
Similarlyflexural and tensile strength also decreases due to increase in crusher
dustpercentage. Slump value decreases if the crusher dust percentage increases. Itwas
concluded that crusher dust may be used instead of sand up to 50% in theplace where
sand availability was less and crusher dust is inplenty.

Ilangovan et al (2008) have conducted tests to study the feasibilityof the usage of
quarry rock dust as hundred percent substitute for natural sandin concrete. Mix design has
developed for M20, M30 and M40 grades forboth conventional concrete and quarry dust
concrete. Tests were conducted oncubes and beams to study the strength and durability of
concrete made ofquarry rock dust and the results were compared with natural sand
concrete.From the test results they reported that permeability of quarry rock dustconcrete
was less compared to controlled concrete. The quarry dust concretehave comparatively
10-15% more strength than the ordinary concrete. Quarrydust concrete has better
durability, little drying shrinkage value and higherwater absorption. They concluded that
the replacement of natural sand withquark rock dust as full replacement.

9
 CHAPTER-4
EXPERIMENTAL INVESTIGATION

4.1 STONEDUST:-

Fig. 4.1 Stone dust

Crushed stone is one of the most accessible natural resources, and is a major
basic raw material used by construction, agriculture, and other industries. Despite the low
value of its basic products, the crushed stone industry is a major contributor to and an
indicator of the economic well-being of a nation. The demand for crushed stone is
determined mostly by the level of construction activity, and, therefore, the demand for
construction materials. Stone resources of the world are very large. High-
purity limestone and dolomite suitable for specialty uses are limited in many geographic
areas. Crushed stone substitutes for road building include sand and gravel, and slag.
Substitutes for crushed stone used as construction aggregates include sand and gravel,
iron and steel slag, sintered or expanded clay or shale, and perlite orvermiculite.
By definition crushed stone is a construction aggregate. It is created by mining a
suitable rock formation and then using a crusher to break down the stone into different
sizes. Even though crushed stone is a low-value commodity it is a good indicator of the
health of an economy since it is widely used in the construction industry. Worldwide
deposits of stone resources are huge. Stone dust is a waste material obtained from crusher
plants. It has potential to be used as partial replacement of natural river sand in concrete.
Use of stone dust in concrete not only improves the quality of concrete but also
conserve the natural river sand for future generations. In the present investigation, an
experimental program was carried out to study the workability and compressive strength
of concrete made using stone dust as partial replacement of fine aggregate in the range of
10% - 100%. Workability and Compressive strength were determined at different
replacement level of fine aggregate viz a viz referral concrete and optimum replacement
level was determined based on compressive strength. Results showed that by replacing
60% of fine aggregate with stone dust concrete of maximum compressive strength can be
10
made as compared to all other replacement levels. The basic tests on stone dust were
conducted as per IS-383-1987 and its specific gravity was around 1.95.
Crushed stone is one of the most accessible natural resources, and is a major
basic raw material used by construction, agriculture, and other industries. Despite the low
value of its basic products, the crushed stone industry is a major contributor to and an
indicator of the economic well-being of a nation.[3]The demand for crushed stone is
determined mostly by the level of construction activity, and, therefore, the demand for
constructionmaterials.[4]
Stone resources of the world are very large. High-purity limestone and dolomite suitable
for specialty uses are limited in many geographic areas. Crushed stone substitutes
for roadbuilding include sand and gravel, and slag. Substitutes for crushed stone used as
construction aggregates include sand and gravel, iron and steel slag, sintered or
expanded clay or shale, and perlite orvermiculite.
Crushed stone is a high-volume, low-value commodity. The industry is highly
competitive and is characterized by many operations serving local or regional markets.
Production costs are determined mainly by the cost of labor, equipment, energy, and
water, in addition to the costs of compliance with environmental and safety regulations.
These costs vary depending on geographic location, the nature of the deposit, and the
number and type of products produced. Crushed stone has one of the lowest average by
weight values of all mineral commodities. The average unit price increased from
US$1.58 per metric ton, f.o.b. plant, in 1970 to US$4.39 in 1990. However, the unit price
in constant 1982 dollars fluctuated between US$3.48 and US$3.91 per metric ton for the
same period. Increased productivity achieved through increased use of automation and
more efficient equipment was mainly responsible for maintaining the prices at this
level.Transportationis a major factor in the delivered price of crushed stone. The cost of
moving crushed stone from the plant to the market often equals or exceeds the sale price
of the product at the plant. Because of the high cost of transportation and the large
quantities of bulk material that have tobe shipped, crushed stone is usually marketed
locally. The high cost of transportation is responsible for the wide dispersion of quarries,
usually located near highly populated areas. However, increasing land values combined
with local environmental concerns are moving crushed stone quarries farther from the
end-use locations, increasing the price of delivered material. Economies of scale, which
might be realized if fewer, larger operations served larger marketing areas, would
probably not offset the increased transportationcosts.
ADVANTAGES:-
 We can use it as a filler with fine aggregate it will reduce your cost.
 It makes cement concrete more economical and environmentfriendly.
 Stone dust being a waste material, useful utilization of it will reducethe
 Environmental strain caused in itsdisposal.
 Stone dust in lieu of river sand in cement concrete in term of strength and
Durability.
DISADVANTAGES:-
3.1.1 If we use complete dust in concrete it getmix and form concrete balls whichis

11
 Not good in concrete mixdesign.
4.1.2 Bleeding of concrete cause less absorption harsh concrete due
tosurface texture ofparticle.

AVAILABILITY:-

4.1.3 Vijaya stone quarries, saifabad,Hyderabad.

4.1.4 Vasu enterpriseschempapet.

Table 3.1 SIEVE ANALYSIS OF STONE DUST

CUMULATIVE STANDARD
WEIGHT CUMULATIVE
SIEVE % OF PASSING % OF
S.NO RETAINED WEIGHT
SIZE WEIGHT % WEIGHT
(gm) RETAINED
RETAINED PASSING

1 4.75mm 4 4 0.4 99.6 100

2 2.36mm 80 84 8.4 91.6 75-100

3 1.18mm 336 420 42.0 58.0 55-90

4 600µ 510 930 93.0 7.0 35-59

5 300µ 70 1000 100.6 0 8-35

TOTAL 243.8

4.1.5Fineness modulus= 243.8/100=2.44

12
Table 4.2 CHEMICAL COMPOSITION OF STONE DUST

CHEMICAL COMPOSITION

CHEMICALS STONE DUST

Silica -SiO2 77.92

Aluminum dioxide- 12.67

Al2O3
Calcium oxide- CaO 2.36

Ferric oxide- Fe2O3 1.98

Sodium oxide- Na2O 1.21

Potassium oxide- K2O 1.08

Magnesium oxide- MgO 0.1

Titanium dioxide- Tio2 0.12

13
4.2. CEMENT
A cement is a binder, a substance used in construction that sets, hardens and
adheres to other materials, binding them together. Cement is seldom used solely, but is
used to bind sand and gravel (aggregate) together. Cement is used with fine aggregate to
produce mortar for masonry, or with sand and gravel aggregates to
produce concrete.Cements used in construction are usually inorganic,
often lime or calcium silicate based, and can be characterized as being either hydraulic
or non-hydraulic, depending upon the ability of the cement to set in the presence of water
(see hydraulic and non-hydraulic lime plaster).Non-hydraulic cement will not set in wet
conditions or underwater; rather, it sets as it dries and reacts with carbon dioxide in the
air. It is resistant to attack by chemicals after setting.Hydraulic cements (e.g.,
Portlandcement) set and become adhesive due to a chemical reaction between the dry
ingredients and water. The chemical reaction results in mineral hydrates that are not very
water- soluble and so are quite durable in water and safe from chemical attack. This
allows setting in wet condition or underwater and further protects the hardened material
from chemical attack. The chemical process for hydraulic cement found by ancient
Romans used volcanic ash (pozzolana) with added lime (calciumoxide).
The word "cement" can be traced back to the Roman term opus caementicium,
used to describe masonry resembling modern concrete that was made from crushed rock
with burnt lime as binder. The volcanic ash and pulverized brick supplements that were
added to the burnt lime, to obtain a hydraulic binder, were later referred to
as cementum, cimentum, cäment, and cement. In modern times, organic polymers are
sometimes used as cements in concrete.
HISTORY
Macedonians and Romans
Lime (calcium oxide) was used on Crete and by the ancient Greeks. There is evidence
that the Minoans of Crete used crushed potshards as an artificial pozzolan for hydraulic
cement.[2]It is uncertain where it was first discovered that a combination of hydratednon-
hydraulic lime and a pozzolan produces a hydraulic mixture (see also:
Pozzolanicreaction), but concrete made from such mixtures was used by the Ancient
Macedonians and three centuries later on a large scale by Romanengineers.
There is... a kind of powder which from natural causes produces astonishing results. It is
found in the neighborhood ofBaiaeand in the country belonging to the towns round about
Mt. Vesuvius. This substance when mixed with lime and rubble not only lends strength to
buildings of other kinds, but even when piers of it are constructed in the sea, they set hard
underwater.
Marcus Vitruvius Pollio, Liber II, De Architecture, Chapter VI "Pozzolana" Sec. 1
The Greeks used volcanic tuff from the island of There as their pozzolan and the Romans
used crushed volcanic ash (activated aluminum silicates) with lime. This mixture was
able to set under water increasing its resistance. The material was called pozzolana from
the town of Pozzuoli, west of Naples where volcanic ash was extracted. In the absenceof

14
pozzolanic ash, the Romans used powdered brick or pottery as a substitute and they may
have used crushed tiles for this purpose before discovering natural sources near
Rome. The huge dome of the Pantheon in Rome and the massive Baths of Caracalla are
examples of ancient structures made from these concretes, many of which are still
standing. The vast system of Roman aqueducts also made extensive use of hydraulic
cement.
CEMENTS IN THE 16TH CENTURY
Tabby, a building material using oyster-shell lime, sand, and whole oyster shells to form
a concrete, was introduced to the Americas by the Spanish in the sixteenthcentury.
CEMENTS IN THE 18TH CENTURY
The technical knowledge for making hydraulic cement was formalized by French and
British engineers in the 18th century.
John Seaton made an important contribution to the development of cements while
planning the construction of the third Eddy stone Lighthouse (1755–59) in the Channel
now known as Seaton’s Tower. He needed a hydraulic mortar that would set and develop
some strength in the twelve-hour period between successive high tides. He performed
experiments with combinations of different limestone’s and additives including trass
and pozzolanasand did exhaustive market research on the available hydraulic limes,
visiting their production sites, and noted that the " hydraulicity" of the lime was directly
related to the clay content of the limestone from which it was made. Seaton was a
civilengineer by profession, and took the idea nofurther.
CEMENTS IN THE 19TH CENTURY
Apparently unaware of Smeaton's work, the same principle was identified by
Frenchman Louis Vicatin the first decade of the nineteenth century. Vicat went on to
devise a method of combining chalk and clay into an intimate mixture, and, burning this,
produced an "artificial cement" in 1817considered the "principal forerunner"of Portland
cement and "...Edgar Dobbs of Southwark patented a cement of this kind in1811."
In Russia, EgorChelievcreated a new binder by mixing lime and clay. His results were
published in 1822 in his book A Treatise on the Art to Prepare a Good Mortar published
in St. Petersburg. A few years later in 1825, he published another book, which described
the various methods of making cement and concrete, as well as the benefits of cement in
the construction of buildings andembankments.
CEMENTS IN THE 20THCENTURY
Calcium aluminate cements were patented in 1908 in France by Jules Bied for better
resistance to sulfates.In the US, the long curing time of at least a month for
Rosendalecement made it unpopular after World War One in the construction of
highways and bridges and many states and construction firms turned to the use of
Portland cement. Because of the switch to Portland cement, by the end of the 1920s of the
15 Rosendale cement companies, only one had survived. But in the early 1930s it was
discovered that, while Portland cement had a faster setting time it was not as durable,
especially for highways, to the point that some states stopped building highways and
roads with

15
cement. Bertrain H. Wait, an engineer whose company had worked on the construction of
the New York City's Catskill Aqueduct, was impressed with the durability of Rosendale
cement, and came up with a blend of both Rosendale and synthetic cements which had
the good attributes of both: it was highly durable and had a much faster setting time. Mr.
Wait convinced the New York Commissioner of Highways to construct an experimental
section of highway near New Paltz, New York, using one sack of Rosendale to six sacks
of synthetic cement. It was proved a success and for decades the Rosendale-synthetic
cement blend became common use in highway and bridgeconstruction.
MODERN CEMENTS
Modern hydraulic cements began to be developed from the start of the
IndustrialRevolution (around 1800), driven by three main needs:

 Hydraulic cement render (stucco) for finishing brick buildings in wetclimates.

 Hydraulic mortars for masonry construction of harbor works, etc., in contact with sea
water.
 Development of strongconcretes.
Modern cements are often Portland cement or Portland cement blends, but other cements
are used in industry.
Table 4.2 CHARACTERISTICS OF CEMENT

PROPERTY CEMENT

SiO3 Content (%) 21.9

Al2O3 Content (%) 6.9

Fe2O3Content (%) 3

CaOContent (%) 63

MgOContent (%) 2.5

SO3Content (%) 1.7

Specific Surface (m2/kg) 370

Specific Gravity 3.15

16
PROPERTIES OF CEMENT
It is always desirable to use the best cement in constructions. Therefore, the
properties of a good cement must be investigated. Although desirable cement properties
may vary depending on the type of construction, generally a good cement possesses
following properties (which depend upon its composition, thoroughness of burning and
fineness of grinding).

 Provides strength tomasonry.

 Stiffens or hardensearly.
 Possesses goodplasticity.
 An excellent buildingmaterial.
 Easilyworkable.
 Good moisture-resistant.

GRADES OF CEMENT 33

GRADEOPC:-

This cement is used for general civil construction work under normal
environmental conditions. The compressive strength of cement after 28 days test as per
BIS specification is 33 MPa. Due to low compressive strength, this cement is normally
not used where high grade of concrete viz, M-20 and above is required. The availability
of higher grades of OPC in the market impacts the usage of 33 grades OPC as these days
43 grade OPC is normally used for general construction work. This grade of cement is
more useful for mass concreting and plain cement concreting and can also be used for
plastering and single storied individualhouses.
Confirming to IS-269.

43 GRADE OPC:-
The 43 grade OPC is the most popular general-purpose cement in the country
today. The production of 43 grade OPC is nearly 50% of the total production of cement
inthe country. Confirming to IS8112-1989.

43 Grade OPC can be used for the following applications:

 General Civil Engineering constructionwork.
 RCC works (preferably where grade of concrete is up toM-30).
 Precast items such as blocks, tiles, pipesetc.
 Asbestos products such as sheets andpipes.
 Non-structural works such as plastering, flooringetc.

53 GRADE OPC:-
53 Grade OPC is a higher strength cement to meet the needs of the consumer for
higher strength concrete. As per BIS requirements the minimum 28 days compressive

17
strength of 53 Grade OPC should not be less than 53 MPa. For certain specialized works,
such as pre-stressed concrete and certain items of precast concrete requiring consistently
high strength concrete, 53 grade OPC is found very useful. 53 grades OPC produce
higher-grade concrete at very economical cement content. In concrete mix design, for
concrete M-20 and above grades a saving of 8 to 10 % of cement may be achieved with
the use of 53 grade OPC.
53 Grade OPC can be used for the following applications. Confirming to IS 12269.
 RCC works(Preferably where grade of concrete is M-25 andabove)
 Precast concrete items such as paving blocks, tiles building blocksetc.
 Pre-stressed concretecomponents
 Runways, concrete Roads, Bridgesetc.
4.3. AGGREGATE
Construction aggregate, or simply "aggregate", is a broad category of coarse to
medium grained particulate material used in construction, including sand, gravel,
crushedstone, slag, recycled concrete and geosynthetic aggregates. Aggregates are the
most mined materials in the world. Aggregates are a component of composite materials
such as concrete and asphalt concrete; the aggregate serves as reinforcement to add
strength to the overall composite material. Due to the relatively high hydraulic
conductivity value as compared to most soils, aggregates are widely used in drainage
applications such as foundation and French drains, septic drain fields, retaining wall
drains, and road side edge drains. Aggregates arealso used as base material under
foundations, roads, and railroads. In other words, aggregates are used as a stable
foundation or road/rail base with predictable, uniform properties (e.g. to help prevent
differential settling under the road or building), or as a low-cost extender that binds with
more expensive cement or asphalt to formconcrete.
The American Society for Testing and Materials (ASTM) publishes an exhaustive
listing of specifications including ASTM D 692 and ASTM D 1073 for various
construction aggregate products, which, by their individual design, are suitable for
specific construction purposes. These products include specific types of coarse and fine
aggregate designed for such uses as additives to asphalt and concrete mixes, as well as
other construction uses. State transportation departments further refine aggregate material
specifications in order to tailor aggregate use to the needs and available supply in their
particular locations.
Sources for these basic materials can be grouped into three main areas: Mining of mineral
aggregate deposits, including sand, gravel, and stone; use of waste slag from the
manufacture of iron and steel; and recycling of concrete, which is itself chiefly
manufactured from mineral aggregates. In addition, there are some (minor) materials that
are used as specialty lightweight aggregates: clay, pumice, perlite, and vermiculite.
HISTORY
People have used sand and stone for foundations for thousands of years.
Significant refinement of the production and use of aggregate occurred during the Roman

18
Empire, which used aggregate to build its vast network of roads and aqueducts. The
invention of concrete, which was essential to architecture utilizing arches, created an
immediate, permanent demand for construction aggregates.
AGGREGATE PROPERTIES
 Aggregatesize
 Toughenedcomposites
 Nancomposites
 Naturalaggregates
 In-situ aggregateformation:

AGGREGATES CLASSIFICATION ACCORDING TO SIZE:-

The size of aggregates used in concrete range from few centimeters or more,
down to a few microns. The maximum size of aggregates may vary, but in each caseit is
to be so graded that the particles of different size fractions are incorporated in the mix in
appropriate proportions. The particle size distribution is called the grading of the
aggregate. According to size the aggregate is classified as: fine aggregate, coarse
aggregate.

FINE AGGREGATE:-
It is the aggregate most of which passes through a 4.75mm IS sieve and contains only
that much coarser material as is permitted by the specifications sand is generally
considered to have a lower size limit of about 0.07 mm. material between 0.06 mm and
0.002mm is classified as silt, and silt smaller particles are called clay. The soft deposit
consisting of sand, silt and clay in about equal proportions is termed loam. The fine
aggregate may be one of the following types.
Natural sand, i.e., the fine aggregate resulting from natural disintegration of
rock and/or that which has been deposited by stream and glacialagencies.
Crushed stone sand, i.e., the fine aggregate produced by crushing hardstone.
Crushed gravel sand, i.e., the fine aggregate produced by crushing natural
gravel.
According to size, the fine aggregate may be described as coarse medium and fine
sands. Depending upon the particle size distribution IS: 383-1970 has divided the fine
aggregate into four grading zones. The grading zones become progressively finer from
grading zone I to grading zone IV

19
COARSE AGGREGATE:
The aggregate most of which are retained on the 4.75 mm IS sieve and contain only
that much of fine material as is permitted by the specifications are termed coarse
aggregate. The coarse aggregates. The coarse aggregate may be one of the following
types:

 Crushed gravel or stone obtained by the crushing of gravel or hardstone.

 Uncrushed gravel or stone resulting from the natural disintegration ofrock.
 Partially crushed gravel or stone obtained as a product of the blending of the above
twotypes.

The graded coarse aggregate is described by its nominal size, i.e., 40mm, 20mm,
16mm and 12.5mm etc.., For example, a graded aggregate of nominal size 12.5mm
means an aggregate most of which passes the 12.5mm IS sieve .Since the aggregates are
formed due to natural disintegration of rocks or by artificial crushing of rock or gravel,
they derive many of their properties from the parent rocks. These properties are chemical
and mineral composition, petro graphic description, specific gravity, hardness, strength,
physical and chemical stability, pore structure, and color. Some other properties of the
aggregates not possessed by the parent rocks are particle shape and size, surface texture,
absorption, etc. All these properties may have a considerable effect on quality of concrete
in fresh and hardenedstates.

4.4. WATER:-
Water is an important ingredient of concrete as it actively participates in the chemical
reaction with cement. Since it helps to form the strength giving cement gel, the quantity
and quality of water is required to be looked into very carefully. In practice, very often
great control on the properties of cement and aggregate is exercised, but the control on
the quality of water is often neglected. Since quality of water affects the strength, it is
necessary for us to go into the purity and quality ofwater.

QUALITIES OF WATER:-
A popular yard-stick to the suitability of water for mixing concrete is that, if water
is fit for drinking it is fit for making concrete. This does not appear to be a true statement
for all conditions. Some water containing a small amount of sugar would be suitable for
drinking but not for mixing concrete and conversely water suitable for making concrete
may not necessarily be fit for drinking. Some specifications require that if the water is not
obtained from source that has proved satisfactory, the strength of concrete or mortar
made with questionable water should be compared with similar concrete or mortar made
with pure water. Some specification also accept water for making concrete if the pH
valueofwaterliesbetween6and8andthewaterisfreefromorganicmatter.Insteadof

20
depending upon pH value and other chemical composition, the best course to find out
whether a particular source of water is suitable for concrete making or not, is to make
concrete with this water and compare its 7 days and 28 days strength with compaction
cubes made with distilled water. If the compressive strength is up to 90%, the source of
water may be accepted. These criteria may be safely adopted in places like coastal area of
marshy area or in other places where the available water is brackish in nature and of
doubtful quality. However, it is logical to know what harm the impurities in water do to
the concrete and what degree of impurity is permissible is mixing concrete and curing
concrete.

Carbonates and bi-carbonates of sodium and potassium effect the setting time of
cement while sodium carbonate may cause quick setting, the bi-carbonates may either
accelerate or retard the setting. The other higher concentrations of these salts will
materially reduce the concrete strength. If some of these salts exceed 1000 ppm, tests for
setting time and 28 days strength should be carried out. In lower concentrations they may
be accepted.

Brackish water contains chlorides and sulphates. When chloride does not exceed
10,000 ppm and sulphate does not exceed 3000 ppm the water with even higher salt
content has been used satisfactorily.

Salts of manganese, tin, zinc, copper and lead cause a marked reduction in
strength of concrete. Sodium iodate, sodium phosphate, and sodium borate reduce the
initial strength of concrete to an extra-ordinary high degree. Another salt that is
determinant to concrete is sodium sulphate and even a sulphide content of 100ppm
warrantstesting.
Silts and suspended particles are undesirable as they interfere with setting,
hardening and bond characteristics. A turbidity limit of 2000 ppm has been suggested.
The initial setting time of the test block made with a cement and water proposed
to be used shall not differ by greater or less than 30 min from the initial setting of the test
block made with same cement and distilledwater.
The following guidelines should take into consideration regarding the quality of
water.
(a) To neutralize 100ml sample of water using phenoplhaline as an indicator, it
should not require more than 5ml of 0.02 normal NaOH.
(b) To neutralize 100ml of sample of water, using mixed indicator, it should not
require more than 25ml of 0.02 normal H2SO4.

21
 CHAPTER- 5
TEST ON CEMENT
GENERAL

5.1. STANDARD CONSISTENCY OFCEMENT

To determine the quantity of water required to produce a cement paste of standard

consistency.

Standard consistency is defined as that consistency which will permit the Vicat’s
plunger to penetrate to a point 5 to 7 mm from the bottom of the Vicat’smould when the
cement is tested.

Fig. 4.1Vicat’s Apparatus

 Vicat’s apparatus, mould,plunger

 Standardtrowel
 Stopwatch
 Weighingbalance

The Vicat’s apparatus consists of a frame and a moving rod weighing 300 mm. The
plunger is kept at the lower end of the rod. It is a cylinder 10 mm. Diameter, A pointer
connected to the rod will move along with it when it is released, over a graduated scale
kept in front of it. The cement past to be tested is kept in the Vicat’smould kept below the
rod on a glass plate.

22
Procedure:

 Carefully weigh 400 gm of cement and place it on a non-porouscup.

 Create a cement paste with 24%of water by the weight ofcement
 Thoroughly mix the cement with water and fill, the Vicatsmould with thepaste.
 The interval from the moment of adding water to the dry cement to the moment of
commencingto fill the mould is known as the time of gauging and shall not be less
than 3 minutes and more than 5 minutes. Lower the plunger gently and test
thepenetration.
 If the penetration is between 5 to 7 mm from the bottom of the mouldthe
quantityof water added is the requiredconsistency.
 Otherwise repeat the test with different percentages of water until the
requiredpenetrationis obtained. Express the amount of water as percentage by
weight of the drycement

CALCULATIONS:
Weight of cementtaken(W1) = 400grams
Weight of water added when the plunger has penetrations of 5 to 7 mm from the bottom
Ofthe mould(W2) =116grams
Percentage of water forstandardconsistency‘P’ = (W2/W1) x 100 =29
Results: percentage of water for standardconsistency is =29%

5.2. FINENESS OF CEMENT:

To determine the fineness of cement.
This test finds out whether the cement is ground properly or not. Fine cement particles

Leads to higher rate of hydration and faster development of strength.

Fig. 4.2 sieve size: 90 microns

23
1. IS Sieve No. 9 (aperture size of 90microns)

2. Tray

3. Spatula

4. Balance

 Weight 100 grams of cement and place it on I.S sieve No9.

 Any air set lumps present in cement are broken usingfingers.
 Sieve gently and continuously for fifteen minutes by hand (not in sieveshaker)
 Weight the residue left which should not be more than 10% of initial weight taken
for acceptablefineness

OBSERVATIONS:

Weight of cement = 100 grams

Weight of cement on sieve = 7 grams

RESULT:The fineness of given sample is 7%

5.3. SETTING TIME OF CEMENT

To determine the initial and final setting time of cement.

The Vicat’s Apparatus, Needle, Annular ring, trays, Balance and weights.

 Preparation of Test Block: Prepare a neat cement paste by gauging the cement
with 0.85 times the water required to give the paste of standard consistency. Start
astopwatchat the instant when water is added to the cement. Fill the vicat’smould
with a cement paste within three to five minutes after addition of water. Fill the
mould completely and smooth off the surface of the paste making it level with the
top the mould. The cement block thus prepared in the mould is test block.
 Clean appliances shall be used for gauging. The temperature of water and that of
the test room at time of gauging shall be within (27 2) 0ͨ
 During the test the block shall be kept at a temperature of (27 2) 0 ͨ and at least90%
relativehumidity

A) DETERMINATION OF INITIAL SETTINGTIME:

Place the test block confined in the mould and resting on the nonporous plate,
under the rod bearing the needle, lower the needle gently in contact with the surface of
the test block and quickly release, allowing it to penetrate intothe test block. In the
beginning the needle will completely pierce the test block. Repeat this procedure untilthe
24
needle, when brought in contact with the test block and released as described above, fails
to pierce the block for 5 to 7 mm measured from the bottom of the mould. The period
elapsing between the time when water is added to the cement and this time shall be initial
setting time.

B) DETERMINATION OF FINAL SETTINGTIME:

Replace the needle of the vicat’s apparatus with the needle with a circular
attachment. The cement shall be considered as finally set, when upon lowering the needle
gently to the surface of the test block the needle makes an impression there on, while the
attachment failto do so. In other words the paste has attained such hardness that the centre
needle does not pierce through the paste more than 0.5mm. the period elapsing between
the time when water is added to the cement and the time at which the needle makes an
impression on the surface on the test block while the attachment fails to do soshall be the
final settingtime

RESULTS:

Initial setting ofthe cement =30minutes

Final setting ofthecement =8 hour 30minutes

5.4. SPECIFIC GRAVITY OF CEMENT:

To determine specific gravity of cement

5.4.1 Specific gravity of cement is defined as the ratio of weight of a given volume
of cement at a given temperature to the weight of an equal volume of
distilled water at the same temperature both weight being, weights being
taken inair.
5.4.2 Specific gravity bottle, weighingbalance
5.4.3 Kerosene free of water, naphtha having a specific gravity not less than 0.7313
shall be used in the specific gravitydetermination.
1. Wt. of empty dry specificgravitybottle = (W1) = 29grams
2. Wt. of bottle +cement (filled 1/4 to1/3 ) = (W2) = 60grams
3. Wt. of bottle +cement (partly filled)+kerosene = (W3) = 90grams
4. Wt. of bottle +kerosene (full) = (W4) = 70grams
5. Wt. of bottle +water(full) = (W5) = 80 grams

Specific gravity ofkerosene SK = (W4 - W1) / (W5 - W1)

(W2-W1) x Sk

Specific gravityofcement =2.62

25
RESULTS: specific gravity of cement =2.62

5.5. COMPRESSIVE STRENGTH OF CEMENT:

To find the compressive strength of given sample of cement.

5.4.4 7.07cm cube moulds( 50cm2 c/s area), compression testing machine,
vibrating machine, balance, weight andtrays.
5.4.5 Measure the given cement and standard sand in the proportion 1:3 byweight.
5.4.6 It shall pass the 850 micron I.S sieve and not more than 10%by weight shall
pass the 600 microns I.S.sieve.
5.4.7 Take 200 grams of cement and 600 grams of standard sand in a pan. Mix it
dry with a trowel for one minute and then add water.
5.4.8 The quality of water shall be (0.25 P + 3) percent of combined weight of
cement and sand, where P is the % of water required to produce a paste of
standard consistency determinedearlier.
5.4.9 Add water and mix it until the mixture is of uniform color. The time of
mixing shall not be less than 3 minutes and not greater than 4minutes.

Fig. 4.3 Compressive strength machine

5.4.10 Immediately after mixing the mortar place the mortar in the cube mould
and tamp with the help of the tamping rod. The mortar shall be rodded 20
times in about 8 seconds to ensure elimination of entrainedair.
5.4.11 If vibrator is used the period of vibration shall be two minutes at the
specified speed of 12000 vibrations perminutes.

26
 5.4.12 Then place the cube mould in an atmosphere of 270ᵒ20 c and 90%
relative humidity submerge in clear fresh water tilltesting.
5.4.13 Take out the cubes from water just before testing. Testing should be
done on their sides without any packing. The rate of loading should be
uniform and 350kg/cm2/minute.
5.4.14 Three cubes should be tested and their average should be taken as the test

result. Report the result inKg/cm2

Results: compressive strength of cement at three days = 17Mpa

I.S. SPECIFICATION: for ordinary Portland cement of grade the crushing strength shall
not be less than 16 Mpa at 3 days, 22 Mpa at 7 days and 33 Mpa at 28 days.

27
 CHAPTER- 5
TEST ON AGGREGATES
5.1 GENERAL

In order to decide the suitability of the aggregate for use in construction, following tests
are carried out:

1. Crushingtest
2. Impacttest
3. Soundnesstest
4. Shape test
5. Specific gravity and water absorptiontest

5.2 CRUSHINGTEST

Fig. 5.1 Crushing Test Setup

One of the model in which pavement material can fail is by crushing under compressive
stress. A test is standardized by IS: 2386 part-IV and used to determine the crushing
strength of aggregates. The aggregate crushing value provides a relative measure of
resistance to crushing under gradually applied crushing load.
The test consists of subjecting the specimen of aggregate in standard mouldto a
compression test under standard load conditions (See Fig-1). Dry aggregates passing
through12.5mmsievesandretained10mmsievesarefilledinacylindricalmeasureof
11.5 mm diameter and 18 cm height in three layers. Each layer is tamped 25 times with at
standard tamping rod. The test sample is weighed and placed in the test cylinder in three
layers each layer being tamped again. The specimen is subjected to a compressive load of
40 tonnes gradually applied at the rate of 4 tonnes per minute. Then crushed aggregates
arethensievedthrough2.36mmsieveandweightofpassingmaterial (W2)isexpressed

28
as percentage of the weight of the total sample (W1) which is the aggregate crushing
value.
Aggregate crushing value = (W1/W2)*100
A value less than 10 signifies an exceptionally strong aggregate while above 35 would
normally be regarded as weak aggregates.

5.3 IMPACTTEST

Fig. 5.2 Impact Test Setup

The aggregate impact test is carried out to evaluate the resistance to impact of aggregates.
Aggregates passing 12.5 mm sieve and retained on 10 mm sieve is filled in a cylindrical
steel cup of internal dia 10.2 mm and depth 5 cm which is attached to a metal base of
impact testing machine. The material is filled in 3 layers where each layer is tamped for
25 numbers of blows (see Fig-3). Metal hammer of weight 13.5 to 14 Kg is arranged to
drop with a free fall of 38.0 cm by vertical guides and the test specimen is subjected to 15
numbers of blows. The crushed aggregate is allowed to pass through 2.36 mm IS sieve.
And the impact value is measured as percentage of aggregates passing sieve (W2) to the
total weight of the sample(W1).
Aggregate impact value = (W1/W2)*100
Aggregates to be used for wearing course, the impact value shouldn’t exceed 30 percent.
For bituminous macadam the maximum permissible value is 35 percent. For Water bound
macadam base courses the maximum permissible value defined by IRC is 40 percent.

5.4 SOUNDNESSTEST
Soundness test is intended to study the resistance of aggregates to weathering action, by
conducting accelerated weathering test cycles. The Porous aggregates subjected to
freezing and thawing is likely to disintegrate prematurely. To ascertain the durability of

29
such aggregates, they are subjected to an accelerated soundness test as specified in IS:
2386 part-V.
Aggregates of specified size are subjected to cycles of alternate wetting in a saturated
solution of either sodium sulphate or magnesium sulphate for 16 – 18 hours and then
dried in oven at 105 to 1100C to a constant weight. After five cycles, the loss in weight of
aggregates is determined by sieving out all undersized particles and weighing.
The loss in weight should not exceed 12 percent when tested with sodium
sulphate and 18 percent with magnesium sulphatesolution.
6.4. SHAPETESTS

Fig. 6.3 Flakiness Gauge

The particle shape of the aggregate mass is determined by the percentage of flaky and
elongated particles in it. Aggregates which are flaky or elongated are detrimental to
higher workability and stability of mixes.
The flakiness index is defined as the percentage by weight of aggregate particles
whose least dimension is less than 0.6 times their mean size. Flakiness gauge (see Fig-4)
is used for this test. Test procedure had been standardized in India (IS: 2386 part-I).
The elongation index of an aggregate is defined as the percentage by weight of particles
whose greatest dimension (length) is 1.8 times their mean dimension. This test is
applicable to aggregates larger than 6.3 mm. Elongation gauge (see Fig-5) is used for this
test. This test is also specified in (IS: 2386 Part-I). However there are no recognized
limits for the elongationindex.

Fig. 6.4 Elongation Gauge

30
6.5. SPECIFICGRAVITY

The specific gravity and water absorption of aggregates are important properties that are
required for the design of concrete and bituminous mixes. The specific gravity of a solid
is the ratio of its mass to that of an equal volume of distilled water at a specified
temperature. Because the aggregates may contain water-permeable voids, so two
measures of specific gravity of aggregates areused:

1. Apparent specific gravityand

2. Bulk specificgravity.

Apparent Specific Gravity, Gapp, is computed on the basis of the net volume of
aggregates i.e the volume excluding water-permeable voids. Thus
Gapp = [(MD/VN)]/W
Where,
MD is the dry mass of the aggregate,
VN is the net volume of the aggregates excluding the volume of the absorbed matter,
W is the density of water.
Bulk Specific Gravity, Gbulk, is computed on the basis of the total volume of
aggregates including water permeable voids. Thus
Gbulk = [(MD/VB)]/W

Where,
VB is the total volume of the aggregates including the volume of absorbed water.
6.6. WATERABSORPTION:
The difference between the apparent and bulk specific gravities is nothing but the
water permeable voids of the aggregates. We can measure the volume of such voids by
weighing the aggregates dry and in a saturated surface dry condition, with all permeable
voids filled with water. The difference of the above two is M W.
MW is the weight of dry aggregates minus weight of aggregates saturated surface dry
condition. Thus,
Water Absorption = (MW/MD)*100
The specific gravity of aggregates normally used in road construction ranges from about
2.5 to 2.9. Water absorption values ranges from 0.1 to about 2.0 percent for aggregates
normally used in road surfacing.

31
 CHAPTER- 7
MIXTURE PROPORTIONS
7.1 MIXDESIGN:-
The mix design was carried out based on the recommended guidelines in Indian
Standards (IS 10262-1982). The basic assumption made in the Indian standard method
formix design is that the compressive strength of workable concrete is by and large
governed by the water-cement ratio. In this method the water content and proportion of
fine aggregate corresponding to a maximum size of aggregate are first determined from
the reference values of workability, water-cement ratio, and the grading of fine aggregate.
The water content and proportion of fine aggregate are then adjusted for any difference in
workability, water/cement ratio and grading of fine aggregate in any particular case.

Grade: M20
Zone:III
C.F = 0.9
Aggregate Size = 20 mm
1) Mean tensile strength Ft = Fck+T.S
Standard deviation For M20 Very good Zone: 4.6
Tensile strength for 5%:1.65
Ft = 20+4.6x1.65
= 27.59 N/mm²
2) W/C ratio from
Graph:0.48
3) % Of Air content for 20 mm aggregate:2%
I.e. 100-2 = 98%
WC = 186 Kg/m³
P = 35%

ADJUSTMENT:

Wc P%

Zone III 0 -1.5

C.F +3 0

W/C 0 -0.024

Total +3 -3.9

32
Watercontent : 186+((186x3)/100) = 191.58 Kg/m³
P% = 35-3.9

= 31.1%

Cementcontent :191.58/0.48

= 399.125Kg//m³

Calculation of fine aggregates:

V = {w+(C/Sc) + (1/P %)(Fa/Sfa)}x1/1000

0.98 = {191.58+ (399.125/3.14)+1/31.1[Fa/2.63]}1/1000

661.310 = (100/31.1) x (fa/2.63)

661.310 = 3.21 x Fa/2.63

205.66 = Fa/2.63

Fa = 540.99 kg/m³

Calculation of coarse aggregates:

V = {w+(C/Sc)+ (1/P%) Fa/Sca}x1/1000

980 = {191.58+399.125/3.14+1/1-31.1(Ca/2.61)}1/1000

661.310 = 100/100-31.1 x Ca/2.61

661.310 = 1.45 x Ca/2.61

Ca = 1189.53 Kg/m³

I.e.

Wc = 191.58 kg/m³

399.125 kg/m³
Cc =

Fa = 540.99 kg/m³

33
Ca = 1189.53 kg/m³

I.e. = W/C : C/C : Fa/C : Ca/C

= (191.58/399.125) : (399.125/399).(125 : 540.99/399.125) :

(1189.53/399.125)

= 0.48 : 1 : 1.355 : 2.980

Calculation of Quantities:

Cube volume = 150 x150 x 150 mm

= 0.15 x 0.15 x 0.15 m

= 0.003375

For 9 cubes: 0.003375 x 9

= 0.030375

Volume required for wastage (15%)

= 0.030375 + [0.030375 x (15/100)]

= 0.03493125

Total quantity = Wc + Cc + Fa +Ca

= 191.58 + 399.125 + 540.99 + 1189.53

= 2321.15 Kgs

Quantity = 2321.15 x 0.03493125

= 81.0806 Kgs

Water content = (191.58 x81.0806) / 2321.15

= 6.6921 Kgs

Cement content = (399.125 x 81.0806)/2321.15

= 13.9419 Kgs

Fine aggregate = (540.99 x 81.0806)/2321.15

= 18.8974 Kgs

34
Coarse aggregate = (1189.53 x 81.0806)/2321.15

= 41.5517 Kgs

Total quantity = 6.6921+13.9419 + 18.8974+41.5517

= 81.08 Kgs

For 9 cubes the quantity of materials requires is

Cement = 13.9419 Kgs
Fine aggregate = 18.8974 Kgs
Coarse aggregate = 41.5517 Kgs
Water = 6.6921 Kgs

35
 CHAPTER -8
TEST ON CONCRETE

8.1 WORKABILITY OF CONCRETE - SLUMP TEST:

To determine the workability of concrete mix of given proportion by slump test.

Iron Pan to mix concrete, weighing machine, trowel, slump cone, scale and tamping rod.
The slump cone is a hollow frustum made of thin steel sheet with internal dimensions as,
the top diameter 10 cm, the bottom diameter 20cm, and height 30cm.It stands on a plane
non-porous surface. To facilitate vertical lifting from molded concrete it is provided with
a suitable guide attachment and suitable foot places and handles. The tamping rod is
16mm dia 60cm long and is bullet pointed at the lowerend.

Unsupported concrete, when it is fresh, will flow to the side and a sinking in
height will take place. This vertical settlement is called slump. Slump is a measure
indicating the workability of cement concrete and also slump gives an idea of W/C ratio
needed for concrete to be used for different works. Slump increases with W/C ratio. A
concrete is said to be workability if it can be easily mixed and easily placed compacted
and easilyfinished.
Mixes are prepared with W/C. ratio 0.48:1:1.355:2.980. For each mix take C.A. =
5.94 kg, F.A. = 2.70 kg, cement = 1.99 kg, water = 0.96 kg.
1. Mix the dry constitution to get a uniform color and then add water.
2. The internal surface of the moulds to be thoroughly cleaned and place on a
smooth, horizontal, rigid and non-absorbent surface.
3. Place the mixed concrete in the cleaned slump cone in 4 layers each
approximately ¼ in height of the mould. The each layer 25 times with tamping
rod.
4. Remove the cone immediately, rising it slowly and carefully in the vertical
direction.
5. As soon as the concrete settlement comes to a stop, measure the subsidence of the
concrete in mm, which gives the slump.

Specifications: As per I.S: 456 the degree of workability is classified as follows

36
 Degree of Workability Slump

Very low 0 mm to 25 mm

Low 25 mm to 50 mm

Medium 50 mm to 100 mm

High 100 to 175 mm

8.2 PREPARATION OFSPECIMENS:

The concrete batch was mixed on a water tight, non-absorbent steel platform with a
shovel, trowel and similar suitable implement, using the followingprocedure.

 The fly ash and fine aggregate were mixed dry until the mixture is thoroughly
blended and is uniform incolor.
 The coarse aggregate was added and mixed with the fly ash and fine aggregate
until the coarse aggregate was uniformly distributed throughout thebatch.

Fig. 7.2 Fine aggregate Fig.7.3Cement

Fig. 7.4 Stone dust Fig. 7.5Coarse aggregate

37
8.3 CURING

Curing of concrete is defined as the process of maintaining the moisture and temperature
conditions of concrete for hydration reaction to normally so that concrete develops
hardened properties over time. The main components which needs to be taken care are
moisture, heat and time during curing process

Curing of concrete is required for the following reasons:

To prevent the concrete to dry out prematurely due to solar radiation and wind. This
prevents plastic shrinkage of concrete. It helps to maintain the concrete temperature by
allowing the hydration process. Hydration process requires water to carry on and releases
heat.

Fig. 8.6 Curing of cubes

Curing helps the concrete to harden and bond with internal materials and
reinforcement. This helps to prevent damage to bond between concrete and reinforcement
due to vibration and impact. This helps development of impermeable, crack free and
durable concrete.

The time to start curing of concrete depends on the evaporation rate of moisture
from the concrete. The evaporation rate is influenced by wind, radiant energy from
sunshine, concrete temperature, climatic conditions, relative humidity.

The evaporation of moisture is driven by the difference in vapor pressure on

concrete surface and the in surrounding air. When the difference is high, evaporation rate
is high.

38
The right time of curing of concrete depends on:

INITIAL CURING – Bleeding of Concrete:

When the concrete is placed and compacted, bleeding of water occurs and rises through
the surface of concrete due to settlement of concrete. The rate and duration of bleeding
depends on many factors including concrete mix properties, depth or thickness of
concrete, method of compaction of concreteetc.

These bleed water starts to evaporate from the surface. When all the bleeding
water has disappeared from the surface, the drying of concrete starts, then initial curingof
concrete is required to minimize the moisture loss and prevent plastic shrinkage cracks to
concrete before and during finishingoperations.

INTERMEDIATE CURING:

Intermediate curing is done when the concrete surface finishing operations has been
carried out before the final setting of concrete. This happens when the required surface
texture of concrete member is achieved rapidly or when the setting of concrete is delayed.

FINAL CURING:

When the concrete is finished after the final setting of concrete, the final curing of
concrete should be done. This helps to prevent surface drying of concrete because the
loss of moisture from the concrete surface occursimmediately.

The curing duration of concrete depends on:

The reasons for curing. i.e. to prevent plastic shrinkage, temperature control, strength and
durability of concrete.

 The size of concrete structural member

 The type of concrete grade and rate of hardening of concrete
 The temperature and moisture conditions of surroundings
 The exposure conditions of the concrete surface during and after curing
 The requirement of curing duration as per specification of concrete

The American Concrete Institute (ACI) Committee 301 recommends a minimum curing
period corresponding to concrete attaining 70 per cent of the specified compressive
strength. The often specified 7 day curing commonly corresponds to approximately 70
per cent of the specified compressive strengths.

The Indian Standard IS 456 – 2000 recommends that curing duration of concrete

39
must be at least 7 days in case of ordinary Portland Cement, at least 10 days for concrete
with mineral admixtures or blended cements are used. It also recommends that the curing
duration should not be less than 10 days for concrete exposed to dry and hot weather
conditions and 14 days for concrete with mineral admixtures or blended cement in hot
and dry weather.

8.4 STRENGTH TEST

Compressive strength of concrete: Out of many test applied to the concrete, this
is the utmost important which gives an idea about all the characteristics of concrete. By
this single test one judge that whether Concreting has been done properly or not.
Compressive strength of concrete depends on many factors such as water-cement ratio,
cement strength, quality of concrete material, and quality control during production of
concrete etc. Test for compressive strength is carried out either on cube or cylinder.
Various standard codes recommend concrete cylinder or concrete cube as the standard
specimen for the test. American society for Testing Materials ASTM C39/C39M provides
Standard Test Method for compressive strength of cylindrical concrete specimens. For
cube test two types of specimens either cubes of 15cm × 15cm × 15cm or 10cm ×10cm
×10 cm depending upon the size of aggregate are used. For most of the works cubical
moulds of size 15cm ×15× 15cm × 15cm are commonly used .These specimens are tested
by compression testing machine after 7days curing, 14 days and 28days curing.

The specimen was tested after the surface gets dried. The load was applied on the smooth
sides without shock and increased continuously till the specimen failed

PROCEDURE FOR COMPRESSIVE TEST

8.4.1 Mix the cement and fine aggregate on a water tight none-absorbent
platform until the mixture is thoroughly blended and is of uniform
color.
8.4.2 Add the stone dust, coarse aggregate and mix with cement and fine
aggregate until the coarse aggregate is uniformly distributed
throughout the batch.
8.4.3 Add water and mix it until the concrete appears to be homogeneous
and of the desired consistency.
8.4.4 Clean the 9 moulds and apply oil/grease gently.
8.4.5 Fill the concrete mix into the moulds with three layers and for every
layer tamping should be done for 25blows.
8.4.6 These blows are tempered properly so as to avoid the voids.
8.4.7 After 24 hours these moulds are removed and test specimens are put in
water for curing.
40
 8.4.8 The top surface of these specimen should be made even and smooth
8.4.9 These specimens are tested by compression testing machine after
7days curing, 14 days curing and 28dayscuring.
8.4.10 Load should be applied gradually at the rate of 140Kg/cm² per minute
till the specimens fails.
8.4.11 Load at the failure divided by area of specimen gives the compressive
strength of concrete.

% OF STONE AVERAGE AVERAGE AVERAGE

DUST WEIGHT OF DENSITY(N/CUM) COMPRESSIVE
REPLACEMENT SPECIMEN(N) STRENGTH
(Mpa)

0% of stone dust 79.59 23582.22 15.53

20% of stone dust 79.85 23484.44 17.29

40% of stone dust 79.65 23600 21.63

60% of stone dust 78.87 23368.88 20.14

80% of stone dust 77.88 69229.62 18.95

Table 7.1 Compressive Strength of Concrete with Stone dust at 7 days

% OF STONE AVERAGE AVERAGE AVERAGE

DUST WEIGHT OF DENSITY(N/CUM) COMPRESSIVE
REPLACEMENT SPECIMEN(N) STRENGTH
(Mpa)

0% of stone dust 75.64 22413.82 18.2

20% of stone dust 77.81 23055.80 20.82

40% of stone dust 78.81 23280.0 23.52

60% of stone dust 77.42 22941.234 23.01

80% of stone dust 76.32 22614.32 20.89

Table 7.2 Compressive Strength of Concrete with Stone dust at 14days

41
 % OF STONE AVERAGE AVERAGE AVERAGE
DUST WEIGHT OF DENSITY(N/CUM) COMPRESSIVE
REPLACEMENT SPECIMEN(N) STRENGTH
(Mpa)

0% of stone dust 77.07 22835.55 22.00

20% of stone dust 78.54 23272.09 22.52

40% of stone dust 78.60 23290.86 26.89

60% of stone dust 79.65 23659.25 25.43

80% of stone dust 78.24 23183.20 23.69

Table 7.3 Compressive Strength of Concrete with Stone dust at 28 days

% OF STONE COMPRESSIVE STRENGTH (N/mm2)

DUST AT 7 DAYS AT 14 DAYS AT 28 DAYS
REPLACEMENT
0% of stone dust 15.53 18.2 22.00

20% of stone dust 17.29 20.82 22.52

40% of stone dust 21.63 23.52 26.89

60% of stone dust 20.14 23.01 25.43

80% of stone dust 18.95 20.89 23.69

Table 7.4 Average Compressive Strength Of Concrete with Stone dust At 7, 14 and 28
days

42
25

20

15

AT 7 DAYS
10

0
0% 20% 40% 60% 80%

Graph 7.1 Compressive Strength of Concrete with Stone dust at 7 days

30

25

20

15
AT 14 DAYS

10

0
0% 20% 40% 60% 80%

Graph 7.2 Compressive Strength of Concrete with Stone dust at 14 days

43
 AT 28 DAYS
30

25

20

15
AT 28 DAYS

10

0
0% 20% 40% 60% 80%

Graph 7.3 Compressive Strength of Concrete with Stone dust at 28 days

30

25

20

AT 7 DAYS
15
AT 14DAYS
AT 28DAYS
10

0
0% 20% 40% 60% 80%

Graph 7.4 Average Compressive Strength Of Concrete with Stone dust At 7, 14 and
28 days

44
 WORKABILITY SLUMP CONE TEST

S.NO % OF STONE DUST SLUMP VALUE

REPLACEMENT BY SAND (mm)
1 0% OF STONE DUST 20

2 20% OF STONE DUST 30

3 40% OF STONE DUST 10

4 60% OF STONE DUST 25

5 80% OF STONE DUST 35

TABLE 7.5 VARIATION IN WORKABILITY BY ADDING DIFFERENT %’S OF

STONEDUST

40
35
30
25
20
SLUMP VALUE
15
10
5
0
0% 20% 40% 60% 80%

GRAPH7.5 VARIATION IN WORKABILITY BY ADDING DIFFERENT %’SOF

STONEDUST

45
 CHAPTER -9
CONCLUSION

From the experimental investigation the following conclusions are made:

The concept of replacement of natural fine aggregate by quarry dust highlighted in

the present investigation could improve the utilization of generated quarry dust, thus
reducing the requirement of land fill area and conserving the scarcely available
natural sand sustainable development.

Strength of the concrete is mainly dependent on bonding of the fine aggregates

which fills the voids between the coarseaggregates.

It is found that the strength of concrete is more for w/c of 0.48 when compared
with w/c of 0.5. As the quantity of water increases, the compressive strength
decreases when replaced with quarrydust.

This is due to the water absorption property of quarry dust. It is well known that
the w/c ratio increases as the strength decreases. But the observation regarding
compressive strength of quarry dust when compared to sand isnonlinear.

From the experimental study, it is concluded that the quarry dust can be used as a
replacement for fine aggregate. It is found that 40% replacement of sand by quarry
dust gives maximum result in strength compared to normal concrete and then
decreases from50%.

The results proved that up to 40% replacement of sand by the quarry dust induced
higher compressive strength and the workability of concrete decreases as
replacement increases. Thus the environmental effects and waste can be
significantlyreduced.

46
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49