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© April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349 -6002 IJIRT 144412 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 103 EXPERIMENTAL STUDY ON HIGH STRENGTH CONCRETE USING SILICA FUME & CERAPLAST 300 Kottu Nagababu 1, Paidi Rajarao 2, Kalam Nagendra Babu 3 and Gannamaneni Ganesh 4 1Assistant professor , Sasi Institute o f Technology & Engineering 2,3,4 Student , Sasi Institute o f Technology & Engineering Abstract —Concrete is one of the essential constriction material used in various works. The research on the concrete properties a nd behavior under various conditions is necessary to proper utilization of it. The high strength concrete is most widely used in the constriction of heavy works. In this work we are test ing the properties of high strength concrete by partial replacement of silica fume with cement and Ceraplast 300, we are preparing mix for high strength concrete and conducted tests for compression and tensile strength, finally we will decide the optimum percentage of silica fume and ceraplast 300 to get the high strength concrete. In this study we optimize the percentage of silica fume in both the aspects of strength and economical .this study we choose M60 grade of concrete and replace silica fume partially with cement by varying percentages such as 0%(control mix),3%,6%,9%,12%,15%,18%.and tested for compressive and tensile strength based on the results.

We finalized the optimum percentage of silica fume. During the last three decades, great strides have been taken in improving the performance of concrete as a construction material. Particularly Silica Fume (SF) and fly ash individually or in combination are indispensable in production of high strength c oncrete for practical application. The use of silica fume as a pozzolana has increased worldwide attention over the recent years because when properly used it as certain percent, it can enhance various properties of concrete both in the fresh as well as in hardened states like cohesiveness, strength, permeability and durability. Silica fume concrete may be appropriate in places where was added (5 -15) % with a increment of 2.5% on a high slump concrete. Joshi [2} observed that are of utmost importance or wh ere very high cohesive mixes are required to avoid segregation and bleeding. Silica fume is a by - product in the production of silicon alloys such as ferro -chromium, ferro -manganese, calcium silicon etc. which also creates environmental pollution and h ealth hazard. From the study carried out by Ray [1] , it is found that compressive strength increased by about 21%, flexural strength by 35% and split tensile strength by 10% when silica fume reduction in cement content at fixed water cement ratio was not detrimental to fresh and hardened concrete properties and may actually improve performance when silica fume was added as 10% by weight of cement content. I. INTRODUCTION During the viaduct construction between J.J hospital and Crawford market in Mumbai, Saini [3] has undergone a research work based on high performance concrete (HPC) of grade M60 where SF was added @15% by weight of cement to ensure durability of the structure. They found 28days compressive strength of HPC varied between 78.6 to 81.3 MPa indicating good control of quality of concrete. Basu (4] developed HPC with SF that can reduce microcracks which tends to develop around the interface between bulk hydrated cement paste and anhydrous cement particles or un reacted pozzolanas. A study has been carried out by Thomas [5] on controlling alkali -silica reaction (ASR) in concrete with particular emphasis on development of a new standard practices in Canada. He concluded that use of blended cement containing low alkali Portland cement mixed with SF would be a via ble means of controllingexpansion in concrete. From the research work done by Lewis [6], it has been observed that there is a considerable reduction in rebound from (35 -15)% by addition of SF which also increased the pumpability of high wokability mix having slump value above 250mm. Incorporation of SF and other admixtures could be important in the production of HPC in order to obtain superior mechanical and durability properties as stated by Roncero [7].He found that water demand of cement – © April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349 -6002 IJIRT 144412 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 104 SF system i n a paste of normal consistency increases with temperature and decreases with incorporation of super plasticizers until a certain dosage. During the extensive research work carried out by Vishnoi [8], it was concluded that SF concrete has a capability to withstand abrasion erosion with better construction feasibility, workability and surface finish. Kanstad [9] made a investigation work to assess the crack sensivity of HPC with different SF contents and found that effect of variation of SF content was of mi nor importance compared to other factors viz degree of insulation, environmental condition. Keeping in view of the above aspects, an attempt has been made to replace cement by SF to develop a cost effective modified concrete, i.e, SF concrete.

Considering this aspect, the present paper reports a study on the effect partial replacement of cement by SF (from 3% to 18% with a step of 3%) on M60 grade concrete designed with 53 grade Ordinary Portland Cement, sand and coarse aggregate. As SF is costl ier than cement, addition to cement will further enhance the cost, which may not be economically viable. The present study has, therefore, made an attempt to use SF as cement replacement materials for high strength concrete (M60) used for major constructio n purposes with a view to achieve the desired strength parameters of the concrete higher grade. Ceraplast 300 is a super plasticizer it is reducing water content without change in workability of concrete. II. EXPERIMENTAL METHOD Materials 53 grade O rdinary Portland Cement, Zone II sand, 12.5 mm and 20 mm down graded aggregate, commercial Silica Fume Grade 920 -D (specific surface = 21.4, bulk density =620 Kg/m3) have been used for various composites. Designed Mix Proportion has been used as (high str ength concrete) 1 : 1.06 : 1.53 for M20 grade concrete with the Mix design for “M60” Grade Design Stipulation Target strength = 68.25 Mpa Max size of aggregate used = 20 mm Specific gravity of cement = 3.15 Specific gravity of fine aggregate = 2.70 Specific gravity of coarse aggregate=2.80 Water absorption of C.A=0.5% Water absorption of F.A=1% Workability is 25mm of slump Step1 Target mean strength fm = f min + ks Where fm = Target mean strength at 28 days. f min = Characteristic Compressive Strength at 28 days k = A statistical value depending upon the results and no of test. s = Standard deviation fm = 60 + 1.65 x 5 = 68.25 N/mm2 Step2 W/c ratio = 0.32 as per IS10262 Considering all facto rs Step3 Selection of water content 20mm size of aggregates -maximum water content 186 liters This is for 125mm slump =186×(3/100)+186 =191.58 lit Step4 Calculation of cement W/c ratio = 0.32 W=191.58lit C=191.58/0 .32 =598.687 Kg/cum From IS456:2000 maximum water content is 450 Kg/cum Step5 Calculation of C.A &F.A From IS456:2000 &IS10262 mix calculations The volume of C.A= 0.58 The volume of F.A=0.42 Step6 Mix proportions Vol.of concrete=1cum Absolute vol.of cement= (450/3.15×1000) =0.142cum Totel volume except aggregates=0.39cum Total volume of aggregates=1 -0.39 =0.61cum Weight of C.A=0.61×0.58×2.8×1000 =990.64 Kg © April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349 -6002 IJIRT 144412 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 105 Weight of F.A=0.61×0.42×2.7×1000 =691.74 Kg Step7 a) Cement = 450 Kg/cum b) Fine aggregate = 691.74 Kg c) coarse aggregate = 990.64Kg d) water = 144lit Super plasticizer: use 1% (1/100) x 144 =1.44lit Total water content = 144 -1.44 = 142.56lit Mix proportion Cement: F.A: C.A: Water 450Kg: 691.74Kg: 990.64Kg: 142.56lit Final mix proportion 1:1.53:2.2 Sample Preparation and Properties Studied Aggregates, Cement and SF have been charged into the mixer machine in succession with appropriate proportions for dry mix followed by addition of water and then rotated sufficiently to achieve uniform and high workable mix. The concrete has been placed in 150 mm cube, 150mm diameter × 300mm high cylinder and 100mm × 100mm × 500mm prism moulds and vibrated with standard vibrator. Curing regime has been taken as 24 hours in mould with hessian clothes at (20 – 24)0 C followed by underwater curing until the day of testing. In the fresh state, compaction factor of each mix have been measured. In hardened state, 3 days, 7 days and 28 days compressive strength of cubes and split tensile strength of cyli nders have been measured. III. TEST RESULTS AND DISCUSSIONS Fresh State: Due to superfine nature of SF particles, SF concrete has shown more cohesiveness than standard ordinary Portland cement concrete. All the mixes have exhibited satisfactory chara cter in relation to segregation and bleeding. But with the increase in percentage of SF, the stickiness in concrete was observed. Workability: In all the mix, the compacting factor, i.e, workability increases as percentage of SF is increased from 5% till 1 0%. SF concrete is just as susceptible to poor workmanship as ordinary concrete and all normal site operations should be performed to the optimum requirements. Test results of compression and tension Sl No. Percent SF replacing cement Compressive strength (N/mm²) Tensile strength (N/mm²) 3days 7days 28days 3days 7days 28days 1 0 20.44 43.11 62.51 2.19 3.67 4.73 2 3 22.66 45.79 65.33 2.40 3.81 4.88 3 6 25.73 47.52 68.24 2.47 3.96 5.02 4 9 27.49 49.53 69.72 2.68 4.10 5.47 5 12 29.74 51.54 71.82 2.82 4.17 5.18 6 15 34.21 56.47 74.45 3.18 4.55 5.3 7 18 31.47 54.68 70.88 3.11 4.31 5.13 Compressive strength results graphs 20.44 22.66 25.77 27.33 29.77 34.23 31.77 43.11 45.77 47.55 49.77 51.55 56.44 54.66 62.15 65.33 68.22 69.77 71.82 74.45 70.88 0 10 20 30 40 50 60 70 80 COMPRESSION STRENGTH N/mm ² 3 D A… © April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349 -6002 IJIRT 144412 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 106 Tensile strength results graphs IV. ECONOMIC ANALYSIS Now according to local rate (Andhrapradesh, India), Cost of Cement = Rs. 6.00 per Kg Cost of Sand = Rs. 0.64 per Kg Cost of Stone chips = Rs. 1.420 per Kg Cost of Silica Fume (Condensed) as supplied by M/s Materials (Mumbai, India) Rs. 16 per Kg. The cost of SF concrete of M60 grade (Only 15% SF by weight of cement) 15% replacement of silicafume=598.687×0.15 = 89.80Kg/cum Total cement per meter cube=598.687 -89.80 =508.88Kg/cum Total cost Cement per cubic meter = 508.88×6 = 3053.28/ - Silica fume per cubic meter = 89.80×16 = 1436.8/ - Fine aggregate per cubic meter =691.74×0.64 =442.71/ - Coar se aggregate per cubic meter =990.64×1.42 =1406.70/ - Total cost per meter cube =3,053.28+1,436.8+442.71+1,406.70 =6,339.5/ - Cost of high strength Concrete of M60 =6,339.5/ - The economic analysis reveals that the target mean strength of next h igher grade concrete namely M70 is achieved in 28 days after replacing 15% of cement by silica fume from the designed mix proportion of M60 grade. Thus, an obvious recommendation can be put forwarded to use the M70 grade of silica fume concrete as a supple ment of M60 grade normal concrete. This is seen from the above cost analysis and which certainly confirms the reduction in the cost of construction of M70 grade SF concrete by about 4.0% in comparison to that of the M60 grade concrete . V. CONCLUSION It may be concluded that use of silica fume is a necessity in production of not only for low/medium strength concrete but also for high strength concrete as this material facilitate the adoption of lower water – cement material ratio and better hydration of cement particles including strong bonding amongst the particles. From the study it has been observed that maximum compressive strength (both cube and cylinder) is noted for 15% replacement of cement with silica fume. As the SF concrete is more compact and thereby more durable in nature and hence with some degree of quality control, it may be used in places of construction where there is a chance of chemical attack, frost action etc. Moreover with 15% of cement replaced by silica fume, the characteristic strength of higher grade of cement concrete namely M70 is achieved only by using the M60 grade designed mix proportion and consequently this SF concrete can certainly be used as a supplement to M60 grade normal concrete with at least 4% of cost reduction. Lastly with good quality control, high early strength can be achieved in SF concrete which may be useful in various structural constructions such as high -rise buildings, bridges, chimneys, machine foundations, run ways etc., wherein, the timeframe of completion vis -à-vis the economy is an important driven factor for the targeted purpose as well as for the contractors and owners alike as this concrete will provides quick stage by stage or floor to floor construction. REFERENCE [1] B. N. krishnaswami :” Durability Aspect of High Performance Concrete.” Indian concrete journal. [2] Sengupta B .”Investigations on the composite structure of silica fume concrete using 2.19 2.4 2.47 2.68 2.82 3.18 3.11 3.67 3.81 3.96 4.1 4.17 4.45 4.31 4.73 4.88 5.02 5.09 5.18 5.3 5.13 0 1 2 3 4 5 6 TENSILE STRENGTH N/mm² 3 D A… © April 2017 | IJIRT | Volume 3 Issue 11 | ISSN: 2349 -6002 IJIRT 144412 INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH IN TECHNOLOGY 10 7 statistical methods ” Cement and Concrete Research,Vol.32, pp.1391 -1394.. [3] Tiwari A. Improving e arly age strength of PSC with indigenous silica fume, The Indian Concrete Journal, October 2000, pp.595 – 98. [4] IS 456:2000, “Plain and Reinforced Concrete - Code of Practice”. Bureau of Indian Standards, New Delhi, India. For Specification of workability te sts [5] IS 383:1970,” from Natural Sources for Concrete”. Bureau of Indian Standards, New Delhi, India. [6] IS 9103 : 1999 : For Specification of admixtures [7] IS 456:2000 & IS : 10262:2009 : For Specification of nominal mix [8] IS 10262 :2009& IS :15388:2003 : For Design mix.