Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

CHAPTER 1
INTRODUCTION

Concrete, being one of the most widely used construction materials, constantly undergoes
refinement to enhance its mechanical properties and sustainability. In recent years, the incorporation
of fibers into concrete matrices has emerged as a promising avenue to augment its strength and
durability. This experimental study focuses on assessing the strength characteristics of concrete
reinforced with mono and hybrid fibers, coupled with the utilization of fly ash as a supplementary
cementitious material.

The integration of fibers, whether singularly (mono) or in combination (hybrid), into concrete
matrices offers several advantages such as improved crack resistance, ductility, and post-crack load-
carrying capacity. Moreover, the addition of fly ash not only enhances the sustainability aspect by
reducing cement consumption but also contributes to the overall performance of concrete by
improving its workability, durability, and long-term mechanical properties.

This experimental study aims to investigate the strength characteristics of concrete reinforced with
Mono (Polypropylene) and Hybrid (Carbon and Polypropylene) fibers, supplemented with Fly-Ash.
Fly-Ash, a byproduct of coal combustion, has gained attention as a supplementary cementitious
material due to its pozzolanic properties and environmental benefits.

This report aims to investigate the impact of varying fiber types, proportions, and combinations on
the compressive strength, flexural strength, and toughness of concrete mixes containing fly ash.
Through a series of meticulously designed experimental procedures and comprehensive analyses,
valuable insights into the mechanical behavior of these composite materials will be elucidated,
paving the way for optimized concrete mix designs tailored towards sustainable and resilient
infrastructure development.

The findings of this study are expected to not only contribute to the existing body of knowledge
concerning fiber-reinforced concrete but also offer practical implications for engineers and
construction professionals seeking innovative solutions for enhancing the performance and
sustainability of concrete structures in diverse applications.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

1.2 FIBER REINFORCED CONCRETE(FRC):

Fiber-reinforced concrete (FRC) is a type of concrete that incorporates fibers to improve its
structural integrity and performance. These fibers are typically made of materials like steel, glass,
synthetic polymers, or natural fibers like cellulose. When mixed into concrete, these fibers enhance
its properties in various ways, such as increasing toughness, reducing cracking, improving
durability, and enhancing resistance to impact and fatigue.

Here are some common uses and benefits of fiber-reinforced concrete:

➢ Enhanced Strength and Durability: The addition of fibers improves the tensile strength of
concrete, making it less prone to cracking and improving its durability over time. This makes
FRC suitable for applications where traditional concrete may not perform as well, such as in
high-traffic areas or structures subjected to environmental stresses.
➢ Crack Control: FRC helps control cracks that may occur due to shrinkage, temperature changes,
or structural loading. The fibers distribute the stresses more evenly throughout the concrete
matrix, reducing the likelihood of cracks and limiting their propagation if they do occur.
➢ Increased Impact Resistance: The presence of fibers enhances the impact resistance of concrete,
making it suitable for applications where impact loads are a concern, such as industrial floors,
pavements, and blast-resistant structures.
➢ Improved Ductility: FRC exhibits greater ductility compared to conventional concrete, meaning
it can undergo more deformation before failure. This property is particularly advantageous in
seismic-prone regions, where structures need to withstand significant lateral forces during
earthquakes.
➢ Reduced Maintenance Costs: By minimizing cracking and increasing durability, fiber-
reinforced concrete can help reduce long-term maintenance costs associated with repairs and
replacements, making it a cost-effective choice for various construction projects.
➢ Versatility: Fiber-reinforced concrete can be used in a wide range of applications, including
residential, commercial, industrial, and infrastructure projects. It is commonly used in building
foundations, pavements, bridge decks, tunnels, precast elements, and shotcrete applications.

Overall, fiber-reinforced concrete offers an attractive combination of strength, durability, and

versatility, making it a preferred choice for many construction projects where enhanced performance
and longevity are desired.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

1.3 OBJECTIVES:

➢ To investigate the influence of Mono Fiber (Polypropylene Fiber) and Hybrid Fibers
(Carbon Fiber+ Polypropylene Fiber) on the Fly-Ash concrete and to develop it as
Construction material.

➢ To find out the workability and near surface characteristics such as Sorptivity for
Polypropylene Fiber and Hybrid-Fiber with 0%,20% and 30% cement replacement with Fly-
Ash.

➢ To study the Strength Characteristics of Fly-Ash concrete by carrying out the Compressive
strength, Flexural strength and Shear strength.

➢ A Comparative Study based on test parameters for Fly-Ash concrete, Polypropylene fiber
concrete and Hybrid Fiber Concrete.

1.4 METHODOLOGY:

1.4.1 MATERIAL SELECTION:

➢ Cement (Dalmia OPC 43 Grade)

➢ Fly-ash
➢ Coarse Aggregate (20 mm and Down size)
➢ Fine Aggregate (River Sand)
➢ SIKA Superplasticizer
➢ Polypropylene Fiber
➢ Carbon Fiber

1.4.2 CONCRETE MIX DESIGN:

➢ M30 Mix design with 0% Fly-ash replaced with cement.

➢ M30 Mix design with 20% Fly-ash replaced with cement.
➢ M30 Mix design with 30% Fly-ash replaced with cement.

1.4.3 WORKABILITY TEST:

➢ Slump Cone Test

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

1.4.4 SPECIMEN PREPARATION AND CURING (90 days):

➢ CUBES (150x150x150mm)
➢ BEAMS (100x100x500mm)
➢ SHEAR CUBES (150x150x150mm with 90x60x150mm wooden block inserted at one
edge)

1.4.5 SPECIMEN TESTING:

➢ Compression Tests.
➢ Flexural Tests.
➢ Shear Tests.
➢ Sorptivity Tests.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

CHAPTER-2

LITERATURE REVIEW
1. B Saketh Raj and M Kanta Rao in their paper entitled “Flexural Performance of Sustainable
Fly Ash Based Concrete Beams”. In their study it was found that in beams with 30% fly-ash
replacing cement had highest load carrying capacity and compressive strength and increased overall
load carrying capacity by 40%. Also, high fly ash concentration activated filler action, refining
pores, and preventing new crack development and existing crack expansion.

2. Gopal Charan Behera et. al. in their paper entitled “Effect of Length of Fibers on Mechanical
Properties of Normal Strength Concrete”. In their study it was found that workability increases
with addition of graded fibers than same volume of long fibers. The mechanical strength of concrete
increases with addition of fibers but decreases in case of long fibers of same volume. The
compressive strength increased by 21.57% and split tensile strength increased by 17.48 %.

3. Poojari Yugendar et. al. in their paper entitled “Strength behavior Analysis of fiber
reinforced fly ash concrete”. In their study it was found that fly ash mitigated strength losses
caused by fiber addition by adjusting workability and reduction of aggregate movement. With the
increase in compressive strength and split tensile strength upto 1.0% steel fiber due to crack
resistance and then decreased as the fiber content increased. The maximum compressive strength
achieved with 1% of steel fiber and 10% Fly-Ash was 5% higher than normal concrete.

4. A. Kistan et. al. in their paper entitled “Study on Flexural Behavior of Polypropylene Fiber
Reinforced Fly-Ash concrete beam”. In their study it was found that addition of 0.4% fibers and
30% replacement of cement with fly-ash showed increase in compressive and split tensile strength
in initial stage, attained 30.22% strength on 7th day and 46.40% on 14th day and reduction of fly-
ash content increases flexural power of PP fiber.

5. Xin Yang et. al., in their paper entitled “An Experimental Study of Shear Resistance for
Multi-Size Polypropylene Fiber Concrete Beams”. In their study it was found that the addition
of PP fiber improved shear-bearing capacity, initial crack shear force, inhibited crack development,
increased crack numbers, reduced crack width, enhanced ductility and toughness, multisize PP fiber
showed better crack resistance compared to coarser type and compared to conventional concrete
beams, PP fiber concrete beams showed increased shear load capacity.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

6. Lihua Xu et. al. in their paper entitled “Experimental Investigation on Damage Behavior of
Polypropylene Fiber Reinforced Concrete under Compression”. In their study it was found that
PF enhances compressive stress-strain behavior of concrete, PFRC's monotonic loading curve aligns
with cyclic response, PF boosts energy dissipation, stiffness and strength, especially at peak stress.
Fibers increase compressive toughness and ultimate strain. Both rise upto 0.15% fiber volume and
PFRC has more shear cracks and its failure is dominated by shear cracking compared to plain
concrete by tensile cracks.

7. Hua Huang et. al. in their paper entitled “Property Assessment of High-Performance
Concrete Containing Three Types of Fibers”. In their study it was found that overall mechanical
properties of HFRC with 3 fibers were better than single FRC, Increase in hybrid fiber volume
decreased compressive strength, HFRC with 25:50:25 fiber ratio has the best hybrid effect and
optimum hybrid fiber volume is 0.12%, reinforcing effect of PP fibers and aramid fibers were better
than carbon fiber, increase in carbon, polypropylene and aramid fiber's volume enhanced tensile
and flexural strength in HFRC.

8. Dan-Yang Su et. al. in their paper entitled “Mechanical and Dynamic Properties of Hybrid
Fiber Reinforced Fly-Ash Concrete”. This research investigated that the polypropylene fiber
affects compressive strength, while basalt fiber impacts split-tensile strength, the addition of
polypropylene hybrid fiber and fly-ash improved concrete integrity after dynamic loading, HBPC
has higher static compressive and split-tensile strength compared to benchmark concrete. Maximum
increment in static compressive and split-tensile strength was found to be 20.87% and 37.65%.

9. Machine Hsie et. al. in their paper entitled “Mechanical Properties of Polypropylene Hybrid
Fiber-Reinforced concrete”. This study investigated the influence of hybrid polypropylene fibers
on concrete's mechanical properties. The hybrid fibers consisted of a combination of staple and
monofilament fibers. Their findings revealed that concrete reinforced with both fiber types exhibited
significant improvement in compressive strength (14.60-17.31% increase), splitting tensile strength
(8.88-13.35% increase), and flexural strength (8.99-24.60% increase) compared to concrete with
only one type of fiber. The polypropylene hybrid fibers also effectively reduced drying shrinkage
strain (0.862 to 0.871). The experiment maintained a constant dosage of staple fibers (0.6 kg/m³)
while incorporating varying amounts of monofilament fibers (3 kg/m³, 6 kg/m³, and 9 kg/m³).

10. Krishna Kumar P et. al. in their paper entitled “Mechanical Properties of Polypropylene
Hybrid Fiber-Reinforced concrete”. In their study it was found that carbon fiber at 2.5% and
polypropylene fiber at 2% showed maximum compressive strength and the addition of

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

polypropylene fiber improved the hydrophobic properties with decrease in absorption and sorptivity
characteristics.

11. Srinivas Rao Naraganti et. al. in their paper entitled that “Durability Study of Hybrid Fiber
Reinforced Concrete”. This study investigated the combined effects of polypropylene fibers and
fly ash on the mechanical properties of M-30 concrete. The researchers added 0.4% polypropylene
fibers by weight of the concrete mix and replaced 30% of the cement content with fly ash. Concrete
cylinders and cubes were cast and tested for compressive and split tensile strength at 7 and 14 days
to assess the impact of this combination. The results revealed that the concrete specimens containing
both polypropylene fibers and fly ash exhibited significant improvement in compressive and split
tensile strength compared to the control concrete specimens without these additives. The most
significant increase was observed in the 14-day compressive strength, which rose by 46.40%
compared to the control group.

12. Muhammad Afaq Javed, et. al. in their paper entitled “An experimental study on Shear
Strengthening of Reinforced Concrete Deep Beams with Carbon Fiber Reinforced Polymers”.
This study investigated the effectiveness of Carbon Fiber Reinforced Polymers (CFRP) in
improving the shear strength of reinforced concrete deep beams. Eight beams were tested, including
control beams with no shear reinforcement, beams strengthened with conventional steel web
reinforcement, and beams strengthened with CFRP sheets in different orientations. Both CFRP and
steel reinforcement increased the load carrying capacity, with CFRP achieving a 32-37% increase
and steel reinforcement achieving a 45% increase. CFRP significantly delayed the appearance of
shear cracks, improving serviceability. Beams with CFRP perpendicular to the cracks showed the
most significant improvement (26-35% increase in load at first crack). However, CFRP failure was
sudden compared to control beams, indicating increased brittleness. Overall, CFRP laminates are a
viable option for strengthening existing structures or reducing steel reinforcement in new ones, but
their brittleness requires careful monitoring.

13. P.B. Sakthivel, et. al. in their paper entitled that “Flexural Performance of Hybrid
Polypropylene-Polyolefin FRC Composites”. Here researchers investigated the flexural
performance of concrete beams reinforced with polypropylene (PO) and polyolefin (PP) fibers, both
individually (mono) and combined (hybrid). The beams were cast with 1% fiber volume fraction
(Vf) of either PP, PO, or a 50-50 mix (PP-PO). The results showed that hybrid fiber beams exhibited
superior flexural strength, ductility, and toughness compared to beams with just PP or PO fibers.
This improvement was evident in higher flexural toughness values and a lower number of cracks.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

The first crack width and ultimate crack width were also significantly reduced in the hybrid beams.
Overall, the study suggests that using a hybrid combination of PP and PO fibers (1% Vf each) leads
to better performing concrete beams in terms of flexural properties and crack resistance compared
to using single fiber types. The study recommends further research on using various fiber types and
aspect ratios in hybrid combinations for concrete and cementitious composites.

14. N. Banthia et. al. in their paper entitled “Hybrid fiber reinforced concrete (HyFRC): fiber
synergy in high strength matrices”. An investigation into the use of multiple fiber types (hybrids)
in high-strength concrete (85 MPa compressive strength) was conducted in this study. The research
compares the flexural toughness of concrete reinforced with various combinations of macro (steel,
polypropylene) and micro (steel, carbon, polypropylene) fibers to single-fiber and control
specimens. The findings indicate that while fiber inclusion doesn't improve compressive strength,
it enhances flexural toughness. Steel macro-fibers outperform polypropylene ones in toughness, and
self-fibrillating polypropylene shows the least improvement. Encouragingly, some hybrid
combinations demonstrated synergy, exceeding the performance of single-fiber counterparts. The
most effective pairings involved crimped polypropylene macro-fibers with micro-fibers (carbon or
2-denier polypropylene), while self-fibrillating polypropylene hybrids showed no synergy. The
study highlights the potential of hybrid fiber-reinforced concrete but emphasizes the need for further
research to optimize fiber combinations for specific applications.

15. Yuhang Du, et. al. in their paper entitled “Experimental study of impact mechanical and
microstructural properties of modifed carbon fiber reinforced concrete”. This study explored
modifying carbon fibers with carbon nanotubes (MCNF) to improve the impact resistance of
concrete. The researchers used electrophoresis to coat carbon fibers with nanotubes and investigated
their dispersion in a concrete environment. Split Hopkinson Pressure Bar tests revealed that MCNF
concrete achieved a 14.0-35.5% increase in dynamic compressive strength compared to regular
concrete, with the optimal MCNF content found to be around 0.3%. Electron microscopy analysis
suggested that MCNF promotes the hydration reaction between cement and the fiber, while also
increasing concrete porosity. The study attributes the strength improvement to the bridging effect
of MCNF, which strengthens with increasing fiber content up to 0.3%. This research proposes
MCNF as a promising reinforcement material for concrete structures requiring high impact
resistance.

16. Vikrant S. Vairagade et. al. in their paper entitled “Hybrid Fiber Reinforced Concrete - A
state of the art review”. This review examines the benefits of using hybrid fiber reinforcement

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

(combining multiple fiber types) in concrete. It highlights that fibers improve concrete's toughness,
energy absorption, and resistance to cracking. The study explores various hybrid combinations,
including steel, polymer, and natural fibers. Overall, the findings suggest that hybrid fiber
reinforcement offers significant advantages compared to single-fiber types. Key benefits include
improved strength, ductility, toughness, and durability. Steel-steel fiber hybrids seem particularly
effective in enhancing tensile and flexural strength. Additionally, hybrid FRC can be more cost-
effective than using single fibers. The review also emphasizes the importance of fiber geometry
(size, length, and shape) on both the fresh and hardened properties of concrete. Finally, the study
underlines the complementary roles of different fiber types within a hybrid system. While high-
durability fibers enhance toughness and long-term performance, smaller fibers address microcracks,
and larger ones tackle macrocracks. This synergistic effect ultimately leads to improved overall
concrete performance.

17. Ahmed M. Tahwia, et. al. in their paper entitled “Optimizing Characteristics of High-
Performance Concrete incorporating Hybrid Polypropylene Fibers”. In their study it was found
that the compressive strength and flexural strength of hybrid polypropylene fiber-reinforced
concrete increased by (1.9 to 12%) and (14.28 to 41.9%), respectively, at age 56 days compared to
control mixture without fibers and the hybridization of 5 kg monofilament and 0.75 kg staple fibers
achieved the highest compressive strength (84.6 MPa), flexural strength (14.9 MPa), and the
optimum impact resistance at age 56 days.

18. Antonio Caggiano, et. al. in their paper entitled “Experimental Characterization of the post-
cracking response in Hybrid Steel/Polypropylene Fiber-Reinforced Concrete”. Researchers
investigated that the influence of combining steel and polypropylene fibers in concrete (Hybrid
Fiber-Reinforced Concrete, HyFRC). The research tested concrete specimens with various ratios of
these fibers (total 0.75% volume) under compression and bending. The addition of fibers had
minimal impact on compressive strength but significantly affected post-cracking behavior in both
compression and bending. Specimens with a higher percentage of steel fibers exhibited increased
post-cracking bending strength and a tougher response, while polypropylene fibers resulted in lower
strength and toughness but reduced variability in test results. The study concludes that combining
these fibers offers a promising approach for tailoring concrete's post-cracking behavior for specific
applications. Further research is recommended to refine the understanding and broaden the use of
HyFRC in practical scenarios.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

19. Piti Sukontasukkul, Phattharachai Pongsopha, Prinya Chindaprasirt, Smith

Songpiriyakij in their paper entitled “Flexural performance and toughness of hybrid steel and
polypropylene fibre reinforced geopolymer”. In their study it was found that for single-type FRC,
both compressive and flexural strength increased with increase in fiber content and for hybrid FRC,
toughness and flexural strength were shown to improve with the percentage of steel fiber
incorporated into mixture. In addition, the improvement appears to decrease when total fiber content
increases above a volume fraction of 1%.

20. Biao Li, Yin Chi, Lihua Xu, Yuchuan Shi, Changning Li in their paper entitled
“Experimental investigation on the flexural behavior of steel-polypropylene hybrid fiber
reinforced concrete”. In their study it was found that an increase in the volume fractions for both
steel and polypropylene fibers lead to an increase in the flexural strengths and post-peak ductility
of concrete and the specimens with hooked-end steel fibers have the highest compressive and
splitting tensile strengths, flexural loads, deflections and toughness, while those with straight fibers
have the lowest values.

21. Rishabh Chaturvedi, et. al. in their paper entitled “Analysis and the impact of polypropylene
fiber and steel on reinforced concrete”. It was found that this investigation finds the impact of
incorporating polypropylene and steel fibers into concrete to create Fiber Reinforced Concrete
(FRC). FRC utilizes short, dispersed fibers to control crack development. Concrete naturally forms
small cracks under stress, which can quickly propagate and reduce overall strength. Polypropylene
fibers help arrest these micro-cracks, while steel fibers further enhance the composite's
performance. The research focuses on the mechanical properties of concrete reinforced with various
fiber combinations. The findings indicate that a combination of 0.25% steel fibers and 0.75%
polypropylene fibers led to the highest compressive strength (77.31 N/mm²), flexural strength (6.15
N/mm²), and split tensile strength (3.91 N/mm²). Additionally, the inclusion of polypropylene fibers
improves fire resistance without affecting the concrete's elastic modulus due to the minimal fiber
content.

22. Hao Bao, et. al. in their paper entitled “Performance evaluation of steel-polypropylene
hybrid fiber reinforced concrete under supercritical carbonation”. In their study it was found
that the compressive strength after carbonation increased by at least 20% and maximum
compressive strength was obtained when the volume fraction of steel and polypropylene fiber was
1.5% and 0% having length dia ratio of steel fiber was 60.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

23. Fangyu Liu, et. al. in their paper entitled “Experimental investigation on the flexural
behavior of hybrid steel-PVA fiber reinforced concrete having fly ash and slag powder”.
Researchers investigated the combined effect of steel and PVA fibers on the bending behavior of
concrete containing fly ash and slag powder. This study investigated the impact of combining steel
and PVA fibers on the flexural behavior of concrete containing fly ash and slag powder. Different
fiber ratios (1:3, 1:1, 3:1) and total fiber contents (1.0% to 3.0%) were tested using four-point
bending tests. Digital Image Correlation (DIC) was employed to track crack formation and
propagation. Results showed that steel fibers significantly improved both flexural strength and
toughness, especially at higher volume fractions (0.5% to 1.5%). PVA fibers, however, exhibited a
more complex effect. While lower PVA content (1.0%) enhanced flexural behavior, a higher content
(1.5%) led to a decrease, potentially due to workability issues. The study suggests that toughness
corresponding to a crack width of L/100 is a more suitable metric to assess the contribution of PVA
fibers, which promote crack resistance through inducing multiple micro-cracks. DIC analysis
revealed that steel fibers bridge macro-cracks, while PVA fibers improve the matrix's crack
resistance. Overall, the study concludes that steel fibers play a more dominant role in enhancing
flexural performance, while the combination of both fibers offers improved crack resistance and
post-peak toughness.

24. Shaikh Faiz Uddin Ahmed, et. al. in their paper entitled “Flexural responses of hybrid steel–
polyethylene fiber reinforced cement composites containing high volume Fly-Ash”. In their
study it was found that hybrid combination of 1.5% steel and 1.0% PVA showed highest flexural
strength and of 0.5% steel and 2.0% PE showed highest deflection and energy absorption capacities.

25. Chella Gifta Christopher, et. al. in their paper entitled “Experimental Toughness and
Durability Evaluation of FRC Composite Reinforced with Steel–Polyester Fiber
Combination”. In their study it was found that hybrid fiber-reinforced concrete made with a
combination of 0.5% steel and 1% polyester fibers improved compressive strength and tensile
strength improved between 26 and 72%.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

CHAPTER-3
PRIOR ART SEARCH
High Volume Fly-Ash Concrete Composition with High Performance, Initial Strength, and
Durability
Inventor: Lee, Seung hoon
Application No.: 1020080045171
A high volume fly-ash concrete composition is provided to ensure proper workability by solving a
problem on viscosity increase according to the reduction of unit number by mixing of silica fume.
Constitution: A high volume fly-ash concrete composition comprises cement, fly ash, silica fume,
high performance water reducing admixture, water, and aggregate. The high volume fly-ash
concrete composition is combined so that fly ash is contained in the amount of 40~80 weight% of
a binding material. Also, the high volume fly-ash concrete composition has unit number
100~150kg/m^3 and unit silica fume amount of 2.5~23.5 kg/m^3. COPYRIGHT KIPO 2010.

Accelerated Set and Hardened Green High Volume Fly Ash Concrete with High
Performance
Inventor: Jiang Chenhui
Hu Danxia
Application No.: 201310182036.1
The invention relates to accelerated set and hardened green high volume fly ash concrete with high
performance. The concrete comprises a gel system which consists of the following materials in parts
by volume: 45-60 parts of silicate cement, 35-50 parts of coal ash and 5-10 parts of limestone flour.
The concrete provided by the invention has the beneficial effects that on the premise that other
properties of the concrete is not basically affected appropriate grinded limestone flour is doped, so
that the gel system of the HVFAGHPC (Green High Volume Fly Ash Concrete with High
Performance) is compounded from binary system to ternary system, and the chemical activity and
the physical nucleation effect of the limestone micro-flour are fully utilized to accelerate the
hydration reaction of a cement and coal ash system, so that the setting time of the HVFAGHPC is
effectively shortened, and the concrete is more applicable to engineering application.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

High-Volume Fly Ash Concrete Composition for Improving the Pumping Ability, and a
Manufacturing Method

Inventor: Lee, Hoe Keun YeoNn, Yeong Hoon

Application No.: 1020100004873

A high-volume fly ash concrete composition and a manufacturing method thereof are provided to
secure the flow ability of concrete with the low amount of water-reducing agent. CONSTITUTION:
A high-volume fly ash concrete composition for improving the pumping ability contains cement,
fly ash, a water-reducing agent, water, and aggregate. 30~80wt% of fly ash including 45~57wt% of
SiO_2 and 6~20wt% of Fe_20_3 is mixed with a binding material. A manufacturing method of the
high- volume fly ash concrete composition comprises the following steps: preparing the cement, the
water-reducing agent, the water, the aggregate, and the fly ash including 45~57wt% of SiO_2 and
6~20wt% of Fe_2O_3; mixing the fly ash with the binding material, to perform a concrete mixing;
and forming the concrete. COPYRIGHT ΚΙΡΟ 2010

Composition of Reaction Accelerator for Fly Ash Concrete, a Manufacturing Method thereof,
and a Fly Ash Concrete Composition Including Reaction Accelerator Composition Capable of
Preventing Deterioration of Concrete Due to Alkali Aggregate Reaction

Inventor: Hashimoto Naoya

Kawaguchi Koji

Application No.: PCT/JP2013/084100

A composition of reaction accelerator for fly ash concrete, a manufacturing method thereof, and a
fly ash concrete composition including reaction accelerator composition are provided to shorten
setting time and setting time of high-volume fly ash concrete with content amount of the fly ash by
including fluoride salt. CONSTITUTION: A composition of reaction accelerator for fly ash concrete
comprises more than one of fluoride salts which are selected from lithium fluoride and aluminium
fluoride. The composition of reaction accelerator for fly ash concrete additionally includes
aluminium sulfate. The composition of reaction accelerator for fly ash concrete can be obtained by
mixing 1-10 weight% of hydrofluoric acid, 1-20 weight% of aluminium hydroxide, 1-10 weight%
of lithium hydroxide, 1-40 weight% of aluminium sulfate, and 20-95 weight% of water. A
manufacturing method of the composition of reaction accelerator for fly ash concrete comprises

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

next steps: adding hydrofluoric acid, aluminium hydroxide, and lithium hydroxide to water;
manufacturing lithium fluoride by performing a reaction with aluminium fluoride at 55-100 deg.

Nanomaterial Enhanced High-Volume Fly Ash Cement and Preparation Method

Inventor: Zhang Bowen

Application No.: 201410819526.2

The invention belongs to the technical field of inorganic nonmetallic materials, and particularly
relates to nanomaterial enhanced high-volume fly ash cement and a preparation method thereof.
The fly ash cement comprises components in parts by weight as follows: 30-70 parts of fly ash, 30-
70 parts of portland cement and 0.02-10 parts of nano SnO2. The problems of discharging and mass
stacking of fly ash are solved, the fly ash cement with high volume of fly ash is provided, the
production process is simple, and the early strength performance is excellent.

High Volume Fly Ash High-Strength Cement Based Composite Material and Preparation
Method

Inventor: Im, Han Jun

Application No.: 1020080045171

The invention provides high volume fly ash high-strength cement based composite material and a
preparation method thereof. The cement based composite material is prepared from the following
components including cement, rutile type nanometer titanium dioxide, fly ash, sands, superfine
copper plating steel fibers, a water reducing agent, a defoaming agent and water. The high volume
fly ash high-strength cement based composite material exerts the filling effect and the crystal
nucleus effect of the nanometer titanium dioxide, utilizes the enhancement mechanism of hybrid
fibers, makes up for strength loss on a cement based material caused by high volume fly ash and
has the characteristics of convenience in production, strong operability, excellent mechanical
properties.

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CHAPTER-4

METHODOLOGY

4.1 MATERIAL USED:

4.1.1 Cement:

Dalmia OPC 43 Grade cement is a type of Portland cement manufactured by Dalmia Cement
(Bharat) Limited, a leading cement producer in India. OPC stands for Ordinary Portland Cement,
which is the most common type of cement used in construction worldwide. The "43 Grade"
designation indicates the compressive strength of the cement after 28 days of curing, which is
typically around 43 megapascals (MPa).

Dalmia OPC 43 Grade cement is made by grinding clinker, gypsum, and other mineral admixtures
to a fine powder. It conforms to the Indian Bureau of Standards (BIS) specifications for OPC 43
Grade cement, ensuring quality and consistency in its properties. This type of cement is suitable for
a wide range of construction applications, including residential, commercial, and industrial projects.

Fig.4.1 Dalmia Cement (Opc43)

Key features and properties of Dalmia OPC 43 Grade cement may include:

➢ Strength: OPC 43 Grade cement offers moderate compressive strength, making it suitable
for general-purpose construction where high strength is not a critical requirement.
➢ Durability: The cement provides good durability and resistance to environmental factors,
ensuring long-lasting performance in various conditions.
➢ Workability: It has suitable workability characteristics, allowing for easy mixing, placing,
and finishing of concrete and mortar.

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➢ Versatility: Dalmia OPC 43 Grade cement can be used in a wide range of applications,
including foundations, columns, beams, slabs, plastering, and masonry work.
➢ Performance: The cement complies with relevant Indian standards and quality assurance
measures, ensuring reliability and consistency in its performance.

Overall, Dalmia OPC 43 Grade cement is a reliable and cost-effective option for construction
projects requiring moderate strength and durability. It is widely used in the Indian construction
industry for its consistent quality and performance.

4.1.2 Aggregates:

In concrete production, aggregates are a fundamental component, constituting the bulk of the
material alongside cement and water. Aggregates are granular materials, which are divided into two
main categories based on their particle size: Coarse aggregates and Fine aggregates.

4.1.2.1 Coarse Aggregates:

➢ Coarse aggregates are larger particles typically greater than 4.75 millimeters (mm) in size,
although specific size ranges may vary depending on local standards and specifications.
➢ They are commonly sourced from natural rock deposits such as limestone, granite, basalt,
or recycled concrete materials.
➢ Coarse aggregates play a vital role in providing structural stability and strength to concrete.
They contribute to the bulk of the concrete volume and are responsible for imparting
mechanical properties such as compressive strength and durability.
➢ Due to their size, coarse aggregates also help to reduce the amount of cement paste required
for a given volume of concrete, thereby improving economy and reducing shrinkage.
➢ Common applications of coarse aggregates include in the production of concrete for
structural elements such as beams, columns, and foundations.

Fig.4.2 Coarse Aggregates

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4.1.2.2 Fine Aggregates:

➢ Fine aggregates consist of smaller particles ranging in size from 0.075 to 4.75 mm, with the
most commonly used size range falling between 0.15 to 4.75 mm.
➢ They are typically composed of natural sand, crushed stone sand, or crushed gravel sand.
Manufactured sand, produced by crushing rocks, is also increasingly used as a fine
aggregate.
➢ Fine aggregates primarily serve to fill the voids between coarse aggregate particles and
cement paste in concrete mixtures. They improve workability, cohesion, and finish ability
of the concrete mix.
➢ Fine aggregates also influence the concrete's properties such as workability, density, and
shrinkage characteristics. They contribute to the formation of a dense matrix, enhancing the
overall strength and durability of concrete.
➢ In addition to concrete production, fine aggregates are also used in mortar, plaster, asphalt
mixes, and as a base material for paving applications.

Both coarse and fine aggregates are crucial constituents of concrete mixes, each playing a distinct
role in determining the properties and performance of the final product. Proper selection and
proportioning of aggregates are essential to achieve the desired concrete properties and meet project
specifications and requirements.

Fig.4.3 Fine Aggregates

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4.1.3 Fly-Ash:
Fly-Ash is a byproduct generated from the combustion of pulverized coal in coal-fired power plants.
It is a finely divided residue that remains after the burning of coal at high temperatures. When coal
is burned, various mineral impurities contained within the coal fuse together and form tiny particles.
These particles are carried up with the flue gases and are collected by electrostatic precipitators or
fabric filters, commonly known as baghouses, before being discharged into the atmosphere. The
collected particles, which constitute fly ash, are then typically stored in silos or ponds.

Fig.4.4 Fly-Ash

There are two primary types of Fly-Ash:

4.1.3.1 Class F Fly-Ash:

➢ Class F fly ash, also known as low-calcium fly ash, is derived from burning anthracite or
bituminous coal. It contains higher levels of silica, alumina, and iron oxide, making it
pozzolanic in nature.
➢ Pozzolanic materials react with calcium hydroxide (lime) in the presence of water and
produce cementitious compounds, contributing to the strength and durability of concrete.
➢ Class F fly ash is typically darker in color and has a higher carbon content compared to Class
C fly ash.

4.1.3.2 Class C Fly-Ash:

➢ Class C fly ash, also referred to as high-calcium fly ash, is produced from burning sub-
bituminous or lignite coal. It contains a significant amount of calcium oxide (lime) in
addition to silica, alumina, and iron oxide.

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➢ Due to its higher calcium content, Class C fly ash exhibits both pozzolanic and self-
cementing properties, which can enhance early strength development and reduce the need
for additional cement in concrete mixes.
➢ Class C fly ash is generally lighter in color compared to Class F fly ash and tends to have
lower carbon content.

Both Class F and Class C fly ash can be utilized as supplementary cementitious materials in concrete
production to improve workability, enhance long-term strength, reduce permeability, and mitigate
alkali-silica reaction (ASR) potential. Additionally, the use of fly ash in concrete contributes to
environmental sustainability by reducing the demand for Portland cement, which is a major source
of greenhouse gas emissions during its production.

4.1.4 Fibers:

Fibers are elongated materials that are significantly longer than they are wide. They can be natural
or synthetic and are used in various industries for their strength, flexibility, and other properties. In
the context of construction materials like concrete, fibers are often added to improve the
performance of the material, enhancing characteristics such as tensile strength, durability, and crack
resistance.

Monofilament Fibers: Monofilament fibers are single, continuous strands typically made from
materials such as polypropylene, polyethylene, nylon, steel, etc. These fibers are uniform in
diameter and are added to concrete mixes to improve properties such as crack resistance, impact
resistance, and durability. Monofilament fibers are commonly used in construction applications
where a single type of fiber is desired.

Hybrid Fibers: Hybrid fibers are a combination of two or more different types of fibers mixed
together in a single concrete mix. This combination allows for synergistic effects, where each type
of fiber complements the others to enhance specific properties of the concrete. For example, a hybrid
fiber mix might combine steel fibers for improved tensile strength with polypropylene fibers for
enhanced crack resistance. Hybrid fibers can offer a more tailored solution to meet the specific
requirements of a construction project, combining the advantages of different fiber types to achieve
optimal performance.

4.1.4.1 DIFFERENT TYPES OF FIBERS:

➢ Steel Fibers: Steel fibers are typically made from carbon steel or stainless steel and are
available in various shapes, such as straight, hooked, crimped, or waved. They are added to

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concrete to improve its tensile and flexural strength, as well as its resistance to cracking and
impact. Steel fibers are commonly used in industrial floors, pavements, tunnel linings, and
precast concrete elements.
➢ Polypropylene Fibers: Polypropylene fibers are synthetic fibers made from thermoplastic
polymers. They are lightweight, non-corrosive, and resistant to alkalis and most chemicals.
Polypropylene fibers are primarily used to control cracking in concrete by reducing
shrinkage cracks and improving freeze-thaw resistance. They are commonly used in
residential and commercial concrete applications such as sidewalks, driveways, and
plastering.
➢ Polyethylene Fibers: Polyethylene fibers are another type of synthetic fiber that offers
similar benefits to polypropylene fibers. They are lightweight, durable, and resistant to
chemicals and moisture. Polyethylene fibers help control cracking and improve durability
in concrete, especially in outdoor applications subject to harsh environmental conditions.
➢ Nylon Fibers: Nylon fibers are synthetic fibers known for their high tensile strength,
elasticity, and abrasion resistance. They are often used in concrete applications where
additional reinforcement is needed, such as in bridge decks, airport runways, and hydraulic
structures. Nylon fibers help improve the impact resistance and toughness of concrete,
reducing the risk of cracking and spalling.
➢ Glass Fibers: Glass fibers are made from molten glass drawn into thin strands. They are
lightweight, non-corrosive, and resistant to chemicals. Glass fibers are used in concrete to
improve its tensile strength, impact resistance, and durability. They are commonly used in
architectural applications, thin-section concrete elements, and decorative panels.
➢ Carbon Fibers: Carbon fibers are high-strength, lightweight fibers made from carbon
atoms. They offer exceptional tensile strength, stiffness, and corrosion resistance. Carbon
fibers are used in specialty concrete applications where extremely high-performance
properties are required, such as in aerospace structures, high-performance composites, and
advanced construction projects.

These are just a few examples of the types of fibers used in construction materials. Each type of
fiber offers unique properties and advantages, allowing engineers and contractors to tailor
concrete mixes to meet specific project requirements and performance criteria.

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4.1.4.2 FIBERS USED:

➢ Polypropylene Fibers: Polypropylene fibers are synthetic fibers made from thermoplastic
polymers. They are lightweight, non-corrosive, and resistant to alkalis and most chemicals.
Polypropylene fibers are primarily used to control cracking in concrete by reducing
shrinkage cracks and improving freeze-thaw resistance. They are commonly used in
residential and commercial concrete applications such as sidewalks, driveways, and
plastering.

Fig.4.5 Polypropylene Fiber

➢ ADVANTAGES OF POYLPROPYLENE FIBER:

Polypropylene fibers offer several advantages when added to concrete mixes for construction
applications:

➢ Crack Control: Polypropylene fibers help control plastic shrinkage cracking and drying
shrinkage cracking in concrete. By reducing the formation and propagation of cracks, they
contribute to the overall durability and longevity of concrete structures.
➢ Improved Durability: The addition of polypropylene fibers enhances the durability of
concrete by increasing its resistance to various forms of deterioration, including abrasion,
freeze-thaw cycles, and chemical attack. This results in concrete that can withstand harsh
environmental conditions more effectively.
➢ Enhanced Toughness: Polypropylene fibers improve the toughness of concrete, making it
more resistant to impact and abrasion. This is particularly beneficial in applications where
concrete is subjected to heavy traffic, dynamic loading, or potential impact events.
➢ Reduced Maintenance Costs: By minimizing cracking and improving durability,
polypropylene fibers help reduce the need for maintenance and repairs over the lifespan of

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concrete structures. This can result in significant cost savings for owners and operators of
infrastructure and buildings.
➢ Improved Workability: Polypropylene fibers can improve the workability of concrete
mixes, making them easier to place, compact, and finish. This can lead to more efficient
construction processes and better-quality finished products.
➢ Corrosion Resistance: Polypropylene fibers are non-corrosive and do not rust, unlike some
metallic reinforcement options. This makes them particularly suitable for concrete exposed
to corrosive environments, such as marine structures or chemical processing facilities.
➢ Lightweight: Polypropylene fibers are lightweight, which simplifies handling and mixing
during concrete production. Their low density also ensures that they do not significantly
affect the overall density or weight of the concrete.
➢ Compatibility: Polypropylene fibers are compatible with various types of concrete mixes
and can be used alongside other admixtures and additives without adverse effects on
performance.

Overall, the addition of polypropylene fibers offers numerous benefits that contribute to the
improved performance, durability, and longevity of concrete structures, making them a popular
choice for a wide range of construction applications.

➢ Carbon Fibers: Carbon fibers are high-strength, lightweight fibers made from carbon
atoms. They offer exceptional tensile strength, stiffness, and corrosion resistance. Carbon
fibers are used in specialty concrete applications where extremely high-performance
properties are required, such as in aerospace structures, high-performance composites, and
advanced construction projects.

Fig.4.6 Carbon Fiber

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➢ ADVANTAGES OF CARBON FIBER:

Carbon fibers offer several advantages when used as reinforcement in construction materials
like concrete:

➢ High Strength-to-Weight Ratio: Carbon fibers are exceptionally strong, with a tensile
strength significantly higher than that of steel. This high strength-to-weight ratio allows for
the creation of lightweight concrete structures that can withstand heavy loads and stresses.
➢ Excellent Durability: Carbon fibers are highly durable and resistant to corrosion, rust, and
degradation from environmental factors. This makes them ideal for use in concrete structures
exposed to harsh conditions, such as marine environments or industrial settings.
➢ Enhanced Flexural Strength: The addition of carbon fibers to concrete improves its
flexural strength, allowing it to better resist bending and cracking under loads. This is
particularly beneficial for structures subjected to dynamic or seismic forces.
➢ Reduced Crack Width: Carbon fibers help control crack propagation in concrete, limiting
the width and extent of cracks that may form due to shrinkage, thermal expansion, or
structural loading. This improves the overall durability and longevity of concrete structures.
➢ Increased Fatigue Resistance: Carbon fibers improve the fatigue resistance of concrete,
enabling it to withstand repeated loading and cyclic stresses without developing cracks or
failures. This is advantageous for structures such as bridges, pavements, and industrial floors
that experience frequent traffic or dynamic loading.
➢ Design Flexibility: Carbon fibers offer designers greater flexibility in creating innovative
and efficient structural designs. Their high strength and low weight allow for the
construction of slender and lightweight structures without compromising performance or
safety.
➢ Ease of Installation: Carbon fiber reinforcement is typically lightweight and easy to handle,
transport, and install on-site. This can lead to faster construction times and reduced labor
costs compared to traditional reinforcement methods.
➢ Environmental Benefits: Carbon fibers have a lower environmental impact compared to
traditional reinforcement materials like steel, as they require less energy to produce and
generate fewer greenhouse gas emissions. Additionally, carbon fiber reinforcement can
extend the service life of concrete structures, reducing the need for frequent repairs or
replacements.

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Overall, the use of carbon fibers as reinforcement in concrete offers numerous benefits,
including increased strength, durability, and design flexibility, while also contributing to more
sustainable and resilient construction practices.

4.1.5 SIKA SUPERPLASTICIZER:

Sika Superplasticizer is a type of concrete admixture manufactured by Sika Group, a leading

provider of specialty chemicals for construction and industry. Superplasticizers, also known as high-
range water reducers, are additives used in concrete mixes to improve workability, reduce water
content, and enhance the performance of concrete.

Fig.4.7 Sika Superplasticizer

Here are some key features and benefits of Sika Superplasticizer:

➢ Improved Workability: Sika Superplasticizer enhances the workability of concrete mixes

by reducing the amount of water needed while maintaining the desired consistency. This
allows for easier handling, placing, and finishing of concrete, leading to improved
construction efficiency and quality.
➢ Increased Strength: By reducing the water-to-cement ratio in concrete mixes, Sika
Superplasticizer helps improve the strength and durability of concrete. This results in
concrete with higher compressive strength and better resistance to cracking, shrinkage, and
other forms of deterioration over time.
➢ Enhanced Flow Properties: Sika Superplasticizer improves the flow properties of concrete,
allowing it to be placed more easily and effectively in congested or complex formwork

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without the need for excessive vibration. This is particularly beneficial for achieving
uniform concrete distribution and filling voids in intricate shapes or tight spaces.
➢ Reduced Permeability: Superplasticizers help reduce the porosity and permeability of
concrete, resulting in improved resistance to water penetration, chloride ingress, and
chemical attack. This enhances the durability of concrete structures, particularly in
aggressive environments such as marine or industrial settings.
➢ Compatibility: Sika Superplasticizer is compatible with various types of cement and
concrete mixes, including Portland cement, blended cement, and specialty cements. It can
be used in a wide range of applications, including ready-mix concrete, precast concrete,
shotcrete, and self-consolidating concrete.
➢ Consistent Performance: Sika Superplasticizer is formulated to provide consistent and
reliable performance in concrete mixes, ensuring uniformity in properties such as
workability, setting time, and strength development. This allows contractors and engineers
to achieve predictable results and meet project specifications with confidence.
➢ Quality Assurance: Sika Superplasticizer complies with relevant industry standards and
regulations, ensuring that it meets stringent quality and performance requirements for use in
construction projects. It undergoes rigorous testing and quality control measures to maintain
its effectiveness and reliability.

Overall, Sika Superplasticizer offers a range of benefits for concrete construction, including
improved workability, strength, durability, and flow properties. Its use can help contractors and
engineers optimize concrete mixes and achieve high-quality, high-performance concrete structures.

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4.2 VARIOUS TESTS CONDUCTED ON MATERIALS

4.2.1 Tests on Cement

Ordinary Portland cement confirming to IS: 8112-2013 is used for the experimental work and the
following tests are conducted as per the standard procedure:
➢ Normal consistency test-IS: 4031(Part-4)-1999
➢ Initial and Final Setting Time- IS: 4031(Part-5)-1999
➢ Specific Gravity of Cement-IS: 4031(Part-11)-2005

4.2.2 Tests on Fine Aggregate

Natural Sand confirming to IS: 383-1970 is used for the experimental work and the few tests are
conducted as per the standard procedure:
➢ Sieve Analysis of Fine Aggregate- IS: 2386(Part-1)-2016
➢ Specific Gravity of Fine Aggregate-IS: 2386(Part-3)-2016

4.2.3 Tests on Coarse Aggregate

Coarse aggregate (20mm downsize) confirming to IS: 383-1970 is used for the experimental work
and the following tests are conducted as per the standard procedure:
➢ Sieve Analysis of Coarse Aggregate-IS: 2386(Part-1)-2016
➢ Specific Gravity of Coarse Aggregate-IS: 2386(Part-3)-2016

4.2.4 Tests on Fly ash

Fly Ash was procured from Bellary Thermal Power Station, KPC Ltd. Kudithini village, Bellary
Taluk and district. (Karnataka). The following tests were carried out:
➢ Specific Gravity of Fly Ash

4.2.5 Tests Conducted on Fresh Concrete

The various tests parameters are conforming to Indian Standards. The test results were taken as an
average of 3 specimens. The Tests Conducted for hardened concrete are as:

➢ Slump Test

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4.3 CONCRETE MIX DESIGN:

4.3.1. M30 Mix design with 0% Fly-ash replaced with cement.

The mix design for M30 grade of concrete is done according to the guidelines of IS 10262-2009.
The detailed design is presented below.

Table 4.1 Mix Design Designations

1 Grade designation M30

2 Type of cement OPC 43 grade
3 Maximum nominal size of Aggregate 20mm and down

4 Minimum cement content 320 Kg/m3 [IS-456:2000, Table 5]

5 Exposure Condition Severe

6 Minimum Water/Cement ratio 0.45

7 Type of aggregate Crushed Angular aggregate

8 Method of Concrete Placing Pumping

9 Workability 100mm(slump)
10 Chemical Admixture type Sika Superplasticizer
11 Maximum Cement 450 Kg/m3

Table 4.2-Specific Gravity of Materials used

Material Specific gravity

Cement 2.72
Fly-Ash 1.63
Fine aggregate 2.81

Coarse aggregate 2.80

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The design steps are as follows:

Step 1: Determination of the target strength for mix proportioning

fck = fck + 1.65s
Where, fck = target compressive strength after 28 days
fck = characteristics compressive strength after 28 days
s = standard deviation. From IS 456-2000, Table 8,
s= 5N/mm2
Hence, the target strength fck = 30 + (1.65 X 5) = 38.25 N/mm2

Step 2: Selection of water /cement ratio: Referring IS 456-2000, Table 5, W/C ratio = 0.45, after
trial mixes W/C is adopted as 0.38.

Step 3: Selection of water content according to IS 10262-2009, Table 2, Maximum water content
for Coarse aggregate with maximum 20mm size = 186 kg/m3.
Quantity of water = 186 for 20mm slump
For 75mm slump the quantity of water can be taken as = 156 KG

Step 4: Determination of cement content: W/C ratio = 0.38 Hence, cement content = 156/0.38=
410.52kg/m3. Incrementing 10%=451.58kg/m3. Adopting 452kg/m3. Referring to IS 456-2000,
Table 5, Minimum cement required = 320 kg/m3<452Kg/m3, Dose of Chemical Admixture = 7KG,
hence the cement content chosen is adequate.

Step 5: Determination of the volume of coarse aggregates Referring IS 10262-2009, Table 3,

volume of coarse aggregate per unit volume of concrete corresponding to a maximum size of coarse
of 20mm and fine aggregate corresponding to grading zone III,
Volume of coarse aggregate = 0.62 for W/C = 0.5
Hence for w/c of 0,45
Volume of coarse aggregate = 0.65
reduced by 10% for pumpable concrete volume=0.59
Volume of fine aggregate = 1-0.59 = 0.41

Step 6: Mix Calculations

➢ Volume of concrete = 1 m3

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➢ Volume of cement = Weight of cement / Specific gravity of cement

= (452/ 2.72) (1/ 103)
= 0.1662 m3
➢ Volume of Fly-Ash = 0m3
➢ Volume of water = Weight of water / Specific gravity of water
= 156/ 1000
= 0.156 m3
➢ Volume of Chemical Admixtures=0.0061 m3
➢ Volume of all in aggregates = (1 – 0.1662– 0.156) = 0.328m3
➢ Thus, all in aggregates = (1-0.328) = 0.6717 m3
➢ Volume of Coarse Aggregates = (0.6717*0.59) = 0.3929 m3
➢ Volume of Fine Aggregates = (0.6717*0.41) = 0.2754 m3
➢ Mass of coarse aggregates = 1100 kg
➢ Mass of fine aggregates = 774kg”
➢ Table 4.3-Summary Mix for M30 with 0% replacement
➢ Table 4.3-Summary Mix for M30 with 0% replacement

Table 4.3 Summary Mix for M30 with 0% replacement

SUMMARY OF MIX MASS FOR 1 CUM PERCENTAGE BY

CONCRETE WEIGHT
GRADE OF CONCRETE M30 -
EXPOSURE CONDITION SEVERE -
CEMENT 452 kg 18%
FLY-ASH 0 kg 0%
WATER 156 kg 6%
CHEMICAL ADMIXTURE 7 kg 0%
FINE AGGREGATES 774 kg 31%
COARSE AGGREGATES 1100 kg 44%
TOTAL 2489 kg 100%

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4.3.2. M30 Mix design with 20% Fly-ash replaced with cement.

The design steps are as follows:

Step 1: Determination of the target strength for mix proportioning

fck = fck + 1.65s
Where, fck = target compressive strength after 28 days
fck = characteristics compressive strength after 28 days
s = standard deviation. From IS 456-2000, Table 8,
s= 5 N/mm2
Hence, the target strength fck = 30 + (1.65 X 5) = 38.25 N/mm2.

Step 2: Selection of water /cement ratio: Referring IS 456-2000, Table 5, W/C ratio = 0.45, after
trial mixes W/C is adopted as 0.38.

Step 3: Selection of water content according to IS 10262-2009, Table 2, Maximum water content
for Coarse aggregate with maximum 20mm size = 186 kg/m3.
Quantity of water = 186 for 20mm slump
For 75mm slump the quantity of water can be taken as = 156 KG

Step 4: Determination of cement content: W/C ratio = 0.38 Hence, cement content = 156/0.38=
410.52kg/m3. Incrementing 10%=451.58kg/m3. Adopting 452kg/m3. Referring to IS 456-2000,
Table 5, Minimum cement required = 320 kg/m3<452Kg/m3, Dose of Chemical Admixture = 7KG,
Fly-Ash Content as per given% is 90KG, Thus Cement Content = 362KG, hence the cement content
chosen is adequate.

Step 5: Determination of the volume of coarse aggregates Referring IS 10262-2009, Table 3,

volume of coarse aggregate per unit volume of concrete corresponding to a maximum size of coarse
of 20mm and fine aggregate corresponding to grading zone III,
Volume of coarse aggregate = 0.62 for W/C = 0.5
Hence for w/c of 0,45
Volume of coarse aggregate = 0.65
reduced by 10% for pumpable concrete volume=0.59
Volume of fine aggregate = 1-0.59 = 0.41

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Step 6: Mix Calculations

➢ Volume of concrete = 1 m3

➢ Volume of cement = Weight of cement / Specific gravity of cement

= (362/ 2.72) (1/ 103)
= 0.1331 m3
➢ Volume of Fly-Ash = 0.0552m3
➢ Volume of water = Weight of water / Specific gravity of water
= 156/ 1000
= 0.156 m3
➢ Volume of Chemical Admixtures=0.0061 m3
➢ Volume of all in aggregates = (1 – 0.1331– 0.156) = 0.3504m3
➢ Thus, all in aggregates = (1-0.3504) = 0.6496 m3
➢ Volume of Coarse Aggregates = (0.6717*0.59) = 0.3800 m3
➢ Volume of Fine Aggregates = (0.6717*0.41) = 0.2663 m3
➢ Mass of coarse aggregates = 1064 kg
➢ Mass of fine aggregates = 748kg”

Table 4.4 Summary Mix for M30 with 20% replacement

SUMMARY OF MIX MASS FOR 1 CUM PERCENTAGE BY WEIGHT

CONCRETE
GRADE OF CONCRETE M30 -
EXPOSURE CONDITION SEVERE -
CEMENT 362 kg 15%
FLY-ASH 90 kg 4%
WATER 156 kg 6%
CHEMICAL ADMIXTURE 7 kg 0%
FINE AGGREGATES 748 kg 31%
COARSE AGGREGATES 1064 kg 44%
TOTAL 2489 kg 100%

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4.3.3. M30 Mix design with 30% Fly-ash replaced with cement.

The design steps are as follows:

Step 1: Determination of the target strength for mix proportioning

fck = fck + 1.65s
Where, fck = target compressive strength after 28 days
fck = characteristics compressive strength after 28 days
s = standard deviation. From IS 456-2000, Table 8,
s= 5 N/mm2
Hence, the target strength fck = 30 + (1.65 X 5) = 38.25 N/mm2.

Step 2: Selection of water /cement ratio: Referring IS 456-2000, Table 5, W/C ratio = 0.45, after
trial mixes W/C is adopted as 0.38.

Step 3: Selection of water content according to IS 10262-2009, Table 2, Maximum water content
for Coarse aggregate with maximum 20mm size = 186 kg/m3.
Quantity of water = 186 for 20mm slump
For 75mm slump the quantity of water can be taken as = 156 KG

Step 4: Determination of cement content: W/C ratio = 0.38 Hence, cement content = 156/0.38=
410.52kg/m3. Incrementing 10%=451.58kg/m3. Adopting 452kg/m3. Referring to IS 456-2000,
Table 5, Minimum cement required = 320 kg/m3<452Kg/m3, Dose of Chemical Admixture = 7KG,
Fly-Ash Content as per given% is 136KG, Thus Cement Content = 316KG, hence the cement
content chosen is adequate.

Step 5: Determination of the volume of coarse aggregates Referring IS 10262-2009, Table 3,

volume of coarse aggregate per unit volume of concrete corresponding to a maximum size of coarse
of 20mm and fine aggregate corresponding to grading zone III,
Volume of coarse aggregate = 0.62 for W/C = 0.5
Hence for w/c of 0,45
Volume of coarse aggregate = 0.65
reduced by 10% for pumpable concrete volume=0.59
Volume of fine aggregate = 1-0.59 = 0.41

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Step 6: Mix Calculations

➢ Volume of concrete = 1 m3

➢ Volume of cement = Weight of cement / Specific gravity of cement

= (316/ 2.72) (1/ 103)
= 0.1162m3
➢ Volume of Fly-Ash = 0.0834m3
➢ Volume of water = Weight of water / Specific gravity of water
= 156/ 1000
= 0.156 m3
➢ Volume of Chemical Admixtures=0.0061 m3
➢ Volume of all in aggregates = (1 – 0.1162– 0.156) = 0.3617m3
➢ Thus, all in aggregates = (1-0.3617) = 0.6383 m3
➢ Volume of Coarse Aggregates = (0.6383*0.59) = 0.3734 m3
➢ Volume of Fine Aggregates = (0.6383*0.41) = 0.2617 m3
➢ Mass of coarse aggregates = 1046 kg
➢ Mass of fine aggregates = 735kg”

Table 4.5 Summary Mix for M30 with 30% replacement

SUMMARY OF MIX MASS FOR 1 CUM PERCENTAGE BY WEIGHT

CONCRETE
GRADE OF CONCRETE M30 -
EXPOSURE CONDITION SEVERE -
CEMENT 316 kg 13%
FLY-ASH 136 kg 6%
WATER 156 kg 7%
CHEMICAL ADMIXTURE 7 kg 0%
FINE AGGREGATES 735 kg 31%
COARSE AGGREGATES 1046 kg 44%
TOTAL 2396 kg 100%

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

4.4 WORKABILITY TEST (SLUMP CONE TEST):

Concrete Slump Test or slump cone test is to determine the workability or consistency of concrete
mix prepared at the laboratory or the construction site during the progress of the work. Concrete
slump test is carried out from batch to batch to check the uniform quality of concrete during
construction. The slump test is the simplest workability test for concrete, involves low cost and
provides immediate results. The Slump Cone consists of tamper (16 mm in diameter and 600 mm
length and with rounded ends), Ruler, Scoop etc.

Fig.4.8 Slump Cone Apparatus

4.5 SPECIMEN PREPARATION AND CURING:

Material Required:

➢ Cube Molds (150x150x150mm)

➢ Beam Molds (100x100x500mm)
➢ Shear Cube Molds (150x150x150mm with 90x60x150mm wooden block inserted at one
edge)
➢ Trowel
➢ Vibrating table (if available)
➢ Curing tank or curing room with controlled temperature and humidity
➢ Plastic sheet or curing compound (if curing tank/room is not available)

Procedure for Specimen Preparation:

Mold Preparation:

➢ Clean the cube molds and apply a thin layer of mold release agent on the inner surfaces to
prevent concrete from sticking.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Mixing Concrete:

➢ Prepare the concrete mix as per the specified mix design.

➢ Ensure the mix is homogenous and has the required workability.

Filling the Molds:

➢ Fill the cube molds with the concrete mix in three equal layers.
➢ Compact each layer using a tamping rod or a vibrating table to eliminate air pockets.

Leveling:

➢ Level the top surface using a trowel, ensuring it is flush with the top of the mold.

Initial Curing:

➢ Cover the molds with a damp cloth or plastic sheet to prevent moisture loss.
➢ Allow the concrete to set for 24 hours in a controlled environment at room temperature.

Demolding:

➢ After 24 hours, carefully demold the concrete cubes.

Procedure for Specimen Curing:

Submerged Curing:

➢ Place the demolded cubes in a curing tank filled with water at 20±2°C.
➢ Ensure the cubes are fully submerged and the water is changed periodically to prevent algae
growth.

Alternative Curing:

➢ If a curing tank is not available, wrap the cubes in wet burlap and plastic sheeting or use a
curing compound.
➢ Maintain the moisture content for the entire curing period.

Curing Duration:

➢ Cure the cubes for 90 days, ensuring continuous moisture.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

4.6 SPECIMEN TESTING:

4.6.1 Compression Strength Test. (As per IS 516:1959 [Reaffirmed 1999])

The compressive strength of concrete is given in terms of the characteristic compressive strength of
150 mm size cubes tested at 28 days (fck)- as per Indian Standards. Characteristic strength of
concrete is the strength of concrete specimens casted and tested as per given code of practice and
cured for a period of 28 days; 95% of tested cubes should not have a value less than this value.

Fig.4.9 Compression Testing Machine

➢ Molds/ Cubes for Testing: The mould shall be of 150 mm size conforming to IS 516:1959
(Reaffirmed 1999).

Fig.4.10 Molds for Testing

Procedure:

➢ All materials shall be brought to room temperature, preferably 27 ± 3 oC before commencing

the test.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

➢ Samples of aggregates for each batch of concrete shall be of the desired grading and shall
be in an air-dried condition. The cement samples, on arrival at the laboratory, shall be
thoroughly mixed dry either by hand or in a suitable mixer in such a manner as to ensure the
greatest possible blending and uniformity in the material. Care being taken to prevent
intrusion of foreign materials.
➢ The proportions of the materials, including water, in concrete mixes used for determining
the suitability of the materials available, shall be similar in all respects to those to be
employed in the work.
➢ The quantities of cement, each size of aggregate, and water for each batch shall be
determined by weight, to an accuracy of 0.1 percent of the total weight of the batch.
➢ The concrete shall be mixed by hand, or preferably, in a laboratory batch mixer, in such a
manner as to avoid loss of water or other materials. Each batch of concrete shall be of such
a size as to leave about 10 percent excess after moulding the desired number of test
specimens.
➢ Each batch of concrete shall be tested for consistency immediately after mixing, by one of
the methods described in IS:1199-1959. Provided that care is taken to ensure that no water
or other material is lost, the concrete used for the consistency tests may be remixed with the
remainder of batch before making the test specimens. The period of re-mixing shall be as
short as possible yet sufficient to produce a homogeneous mass.
➢ Test specimens cubical in shape shall be 15 × 15 × 15 cm. If the largest nominal size of the
aggregate does not exceed 2 cm, 10 cm cubes may be used as an alternative. Cylindrical test
specimens shall have a length equal to twice the diameter. They shall be 15 cm in diameter
and 30 cm long. Smaller test specimens shall have a ratio of diameter of specimen to
maximum size of aggregate of not less than 3 to 1, except that the diameter of the specimen
shall be not less than 7·5 cm for mixtures containing aggregate more than 5 percent of which
is retained on IS Sieve 480.
➢ The test specimens shall be made as soon as practicable after mixing, and in such a way as
to produce full compaction of the concrete with neither segregation nor excessive laitance.
The concrete shall be filled into the mould in layers approximately 5 cm deep. In placing
each scoopful of concrete, the scoop shall he moved around the top edge of the mould as the
concrete slides from it, in order to ensure a symmetrical distribution of the concrete within
the mould. Each layer shall be compacted either by hand or by vibration.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

➢ The test specimens shall be stored in a place, free from vibration, in moist air of at least 90
percent relative humidity and at a temperature of 27° ± 2°C for 24 hours ± ½ hour from the
time of addition of water to the dry ingredients.
➢ The ends of the specimen shall be capped before testing. The material used for the capping
shall be such that its compressive strength is greater than that of the concrete in the core.
Caps shall be made as thin as practicable and shall not flow or fracture before the concrete
fails when the specimen is tested. The capped surfaces shall be at right angles to the axis of
the specimen and shall not depart from a plane by more than 0·05 mm.
➢ The bearing surfaces of the testing machine shall be wiped clean and any loose sand or other
material removed from the surfaces of the specimen which are to be in contact with the
compression platens.
➢ In the case of cubes, the specimen shall be placed in the machine in such a manner that the
load shall be applied to opposite sides of the cubes as cast, that is, not to the top and bottom.
➢ The axis of the specimen shall be carefully aligned with the centre of thrust of the spherically
seated platen. No packing shall be used between the faces of the test specimen and the steel
platen of the testing machine.
➢ The load shall be applied without shock and increased continuously at a rate of
approximately 140 kg/sq cm/min until the resistance of the specimen to the increasing load
breaks down and no greater load can be sustained.
➢ The maximum load applied to the specimen shall then be recorded and the appearance of
the concrete and any unusual features in the type of failure shall be noted.

𝑃
The formula use for compression strength,
𝐴

Where, P= Failure load

A=Cross-sectional area.
4.7.2 Flexural Strength Test: (As per IS 516:1959 [Reaffirmed 1999])

The flexural strength test of concrete, also known as the modulus of rupture test, measures the ability
of a concrete beam or slab to resist failure in bending. This test is critical for structures like
pavements and slabs, where bending stresses are common.

The concrete beam specimen consists of dimensions are100 mm x 100 mm x 500 mm.

Preparation of Specimen:

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

➢ The concrete beam specimen is cast and cured as per standard procedures. Typically, curing
is done for 28 days.
➢ Before testing, the specimen is removed from the curing environment and allowed to reach
room temperature.

Setting Up the Test:

➢ Place the specimen on the support blocks of the testing machine. For a center-point loading
test, the specimen should be supported at both ends with a span length of three times the
depth of the beam (typically 450 mm for a 150 mm deep beam). For a third-point loading
test, the span is the same, but the load is applied at two points, each one-third of the span
length from the ends.
➢ Ensure that the specimen is properly aligned and that the supports and loading blocks are
free of any debris.
➢ Gradually apply the load to the specimen at a constant rate. For a center-point loading test,
the load is applied at the midpoint. For a third-point loading test, the load is applied at two
points.
➢ Continue to apply the load until the specimen fails. Record the maximum load applied.

Calculating Flexural Strength:

➢ For a center-point loading test, the flexural strength is calculated using the formula:

Where;
P=Maximum load applies(N)
L=Span length(mm)
b=Width of Specimen(mm)
d=Depth of Specimen(mm)

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 4.11 Flexure Testing Machine

4.7.3 Shear Strength Test

Shear strength of concrete was determined by applying direct shear force on push-off specimen.
The specimen consists of 150x150x150mm with 90x60x150mm wooden block inserted at one edge.
The test for determining shear transfer strength for concrete employs a specimen which is subjected
to uniaxial compression in a compression-testing machine. Shear strength of concrete is the ratio of
ultimate shear force at which the specimen fails to the shear area of push-off specimen. The
specimens were designed so as to ensure that the failure of concrete occurs in shear at the shear
plane and undesirable failure modes due to bending or compression are avoided. Typical dimensions
of push-off specimen and a failed specimen along the shear plane during loading.
Ultimate shear force
Shear Strength (τ) = Shear area
Pl1
Maximum applied force in shear plane, P2 = l
1 +l2

Where, P = Applied load

l1 and l2 = Length of applied load between the rods

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 4.12 Shear specimen arrangement and dimensions.

4.7.4 Sorptivity Tests:

Sorptivity test is also considered as an indicator of durability of concrete. The amount of moisture
that permeates concrete by unidirectional capillary flow is measured by sorptivity.
After 28 days of curing, cube specimens of 150 x 150 x 150 mm are subjected to a sorptivity test.
The cube specimens are allowed to cool to room temperature and stored in tray with microscopic
supports, with just the bottom 5 mm of each specimen immersed in water, following a 24-hour oven
drying process at 105°C. Darker coloration appeared at regular intervals of 15 minutes for 4 hours,
signifying an increase in water level. The sorptivity is calculated as follows;
S= i
√t
Where, S sorptivity in mm/min
i = increase in water level (mm)
t = time taken for this rise (min)

DEPARTMENT OF CIVIL ENGINEERING,

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

CHAPTER-5

RESULTS AND DISCUSSIONS

5.1 Tests on Materials

5.1.1 Cement

5.1.1.1 Normal Consistency test observations:

Mass of Cement taken: 300g

Table 5.1 Normal Consistency of Cement

Penetration of
Mass of Water, Water,
needle,
Cement, gm cc %
mm
300 84 28 29
300 90 30 15
300 102 34 3
300 96 32 6

Weight of water added*100

Normal consistency=
Weight of cement taken

➢ Normal Consistency of Cement is 32%.

➢ The percentage of water required for preparing a cement paste of standard consistency is 26%
to 32%.

5.1.1.2 Initial setting Time Observations:

Table 5.2 Initial Setting Time of Cement

Penetration from
Time, min
top of mould, mm
0 0
10 0
20 0
30 0
35 1
38 2
40 4
42 6
➢ The Initial Setting time of Ordinary Portland Cement is 42 min.
➢ For Ordinary Portland Cement, Initial Setting time should not be less than 30 minutes.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.1.1.3 Specific Gravity Test Observations: (Cement)

Table 5.3 Specific Gravity of Cement
Mass of empty Bottle, WI 41 43
Mass of Bottle + Water, W2 146 150
Mass of Bottle + Kerosene, W3 122 129
Mass of Cement, W4 50 50
Mass of Bottle + Cement + Kerosene, 157 165
W5 g
W3-W1 122-41
Specific Gravity of Kerosene= = =0.77
W2-W1 146-41

W3-W1 129-43
= = =0.80
W2-W1 150-43

W4∗(W3−W1) 50∗(122−41)
Specific Gravity of Cement = (W4+W3−W5)∗(W2−W1)
= (50+122−157)∗(146−41)
= 2.57

W4∗(W3−W1) 50∗(129−43)
= (W4+W3−W5)∗(W2−W1) = (50+129−165)∗(150−43)
= 2.87

2.57+2.87
Average Specific Gravity of Cement= =2.72
2

➢ Specific Gravity of Cement is 2.72 fly-ash is 1.79.

➢ Specific Gravity of Cement lies in the range 2.5 to 3.15.

5.1.1.4 Specific Gravity Test Observations: (Fly-ash)

Table 5.4 Specific Gravity of Cement

Mass of empty Bottle, WI 32 34
Mass of Bottle + Water, W2 128 130
Mass of Bottle + Kerosene, W3 109 112
Mass of Cement, W4 50 50
Mass of Bottle + Cement + Kerosene, 137 139
W5 g
W3−W1 109−32
Specific Gravity of Kerosene = W2−W1
= 128−32
= 0.80

W3 − W1 112 − 34
= = = 0.81
W2 − W1 130 − 34

W4∗(W3−W1) 50∗(109−32)
Specific Gravity of Fly − ash = (W4+W3−W5)∗(W2−W1)
= (50+109−137)∗(128−32)
= 1.82

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

W4∗(W3−W1) 50∗(112−34)
Specific Gravity of Fly − ash = (W4+W3−W5)∗(W2−W1) = (50+112−139)∗(130−34)
= 1.76

1.82 + 1.76
Average Specific Gravity of Fly − ash = = 1.79
2

➢ Specific Gravity of fly-ash is 1.79.

➢ Specific Gravity of Cement lies in the range 2.1 to 3.0.

5.1.1.5 Fineness of Cement Observations:

Table 5.5 Fineness of cement

Mass of Cement taken, 100

Mass of residue after sieving, 4

Mass of residue 4
Fineness = = 100 = 4%
100

➢ Fineness of Cement is 4%.

➢ For Ordinary Portland Cement, the residue by mass on IS test sieve should not exceed 10%.

5.1.2 Fine Aggregate

5.1.2.1 Sieve analysis observations:

Mass of Fine aggregate: 1000g

Table 5.6 Sieve analysis of fine aggregates

IS Sieve Weight of Cumulative % of weight % of weight

size sand retained, weight, gm retained, % passing, %
gm
4.75mm 137 137 13.7 86.3
2.36mm 209 346 34.6 65.4
1.18mm 374 720 72.0 28.0
600 micron 109 829 82.9 17.1
300 micron 83 912 91.2 8.8
150 micron 62 974 97.4 2.62
PAN 26 1000 100.0 0
= 1000

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

𝑆𝑢𝑚𝑚𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑐𝑢𝑚𝑢𝑙𝑎𝑡𝑖𝑣𝑒 % 𝑤𝑒𝑖𝑔ℎ𝑡 𝑟𝑒𝑡𝑎𝑖𝑛𝑒𝑑 391.4

𝐹𝑖𝑛𝑒𝑛𝑒𝑠𝑠 𝑀𝑜𝑑𝑢𝑙𝑢𝑠 = = = 3.914
100 100

➢ Fineness Modulus of Fine aggregate is 3.91

➢ Fine Aggregate with Fineness Modulus between 2.6 to 2.9 is categorized as medium sand and
belongs to Zone-I according to Table 4 of IS: 383-2016.

5.1.2.2 Specific Gravity Test Observations:

Table 5.7 Specific Gravity of Fine Aggregates

Mass of empty pycnometer, W1, 498

Mass of pycnometer + sand, W2 1025
Mass of pycnometer + sand + water, W3 1840
Mass of pycnometer + water, W4 g 1500

(W2 − W1) (1025 − 498)

Specific Gravity of sand = = = 2.81
(W2 − W1) − (W3 − W4) (1025 − 498) − (1840 − 1500)

➢ Specific Gravity of fine Aggregate is 2.81

➢ Specific Gravity of Fine Aggregate lies in the range 2.6 to 2.75.

5.1.3 Coarse Aggregate

5.1.3.1 Sieve Analysis Observations:

Mass of Fine aggregate: 5000g

Table 5.8 Sieve analysis of coarse aggregates

IS Sieve size Weight Cumulative % of weight % of weight

retained, gm weight, gm retained, % passing, %
20 5000 5000 100 0
10 0 5000 100 0
4.74 0 5000 100 0
PAN - - - -

Summation of cummulative % weight retained 300

Fineness Modulus = = =3
100 100

➢ Fineness Modulus of aggregate is 3.

➢ Coarse Aggregate with Fineness Modulus 3.5 to 6.5 is categorized as medium sand and
belongs to Zone 11 according to Table 2 of IS: 383- 201

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.1.3.2 Specific Gravity Test Observations:

Table 5.9 Specific gravity of fine aggregates

Mass of saturated dry sample, W1, 396 396 396

Mass of basket suspended in water, W2 1080 1083 1089
Mass of basket + material, W3 1610 1611 1616
Mass of Agg. Suspended in water, W4 g 1170 1170 1170
Specific Gravity, S 2.80 2.79 2.82
Average specific gravity, S 2.80

(W2 − W1)
Specific Gravity of sand =
(W2 − W1) − (W3 − W4)

= 2.80

=2.79

=2.82

2.80 + 2.79 + 2.82

Specific Gravity of sand = = 2.80
3

➢ Specific Gravity of fine Aggregate is 2.80

➢ Specific Gravity of Fine Aggregate lies in the range 2.6 to 2.75.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.2 Compressive Strength of Cubes:

Table 5.10 Compression test on mono FRC cubes

Compression test on mono FRC cubes

Avg.
Mix Design Specimen Failure Strength
Strength
(M30) Designation Load (kN) (N/mm2)
(N/mm2)
0% Fly-ash
0-PPF1 593.00 26.36
M1 0-PPF2 580.00 25.78 25.91
0-PPF3 576.00 25.60
20% Fly-ash
20-PPF1 603.00 26.80
M2 20-PPF2 600.00 26.67 26.67
20-PPF3 597.00 26.53
30% Fly-ash
30-PPF1 676.00 30.00
M2 30-PPF2 691.00 30.71 30.70
30-PPF3 706.00 31.38

Table 5.11 Compression test on hybrid FRC cubes

Compression test on hybrid FRC cubes

Avg.
Mix Design Specimen Failure Strength
Strength
(M30) Designation Load (kN) (N/mm2)
(N/mm2)
0% Fly-ash
0-PPF+CF1 694.00 30.84
M1 0-PPF+CF2 698.00 31.02 30.99
0-PPF+CF3 700.00 31.11
20% Fly-ash
20-PPF+CF1 878.00 39.02
M2 20-PPF+CF2 900.00 40.00 40.00
20-PPF+CF3 922.00 40.98
30% Fly-ash
30-PPF+CF1 1053.00 46.80
M2 30-PPF+CF2 958.00 42.58 43.67
30-PPF+CF3 937.00 41.64

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Compression Test on Mono and Hybrid Fiber Cubes:

Table 5.12 Compression test on mono and hybrid FRC cubes

Percentage Percentage
increase of increase of
0% Fly-ash, 20% Fly-ash,
Avg. Values 30% Fly-ash, compressive compressive
N/mm2 N/mm2
N/mm2 strength for 20% strength for 30%
fly-ash (%) fly-ash (%)
PPF 25.98 26.67 30.71 2.66 18.21

PPF+CF 30.98 40.00 44.22 29.12 42.74

Compressive Strength of Cubes

50.00
43.67
Compressive Strength, N/mm2

45.00
40.00
40.00
35.00 30.99 30.71
30.00 25.91 26.67
25.00
20.00
15.00
10.00
5.00
0.00
0% Fly-ash 20% Fly-ash 30% Fly-ash

PPF PPF+CF

Fig.5.1 Graphical representation for compressive strength

Observations:

➢ Compressive strength test results showed that the addition of fly ash had a positive impact
on the compressive strength of mono FRC (PPF-1%). At 20% fly ash replacement showed
2.66% increase in strength, while at 30% replacement resulted in a more substantial
increase of 18.21%, compared to the mix without fly ash.
➢ The effect of fly ash on hybrid FRC (PPF-0.5% + CF-0.5%) followed a similar pattern.
The incorporation of 20% fly ash resulted in a 29.12% improvement in shear strength and
30% fly ash yielded a higher increase of 40.74% shear strength as compared to the mix
without fly ash.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.3 Flexural Strength of Beams:

Table 5.13 Flexural test on mono FRC cubes

Flexural Test on Mono FRC Beams

Avg.
Mix Design Specimen Failure Strength
Strength
(M30) Designation Load (kN) (N/mm2)
(N/mm2)
0% Fly-ash
0-PPF1 15.00 6.00
M1 0-PPF2 16.00 6.40 6.40
0-PPF3 17.00 6.80
20% Fly-ash
20-PPF1 18.00 7.20
M2 20-PPF2 19.00 7.60 7.60
20-PPF3 20.00 8.00
30% Fly-ash
30-PPF1 21.00 10.71
M2 30-PPF2 20.00 9.96 10.31
30-PPF3 21.00 10.27

Table 5.14 Flexural Test on Hybrid FRC Cubes

Flexural Test on Hybrid FRC Beams

Avg.
Mix Design Specimen Failure Strength
Strength
(M30) Designation Load (kN) (N/mm2)
(N/mm2)
0% Fly-ash
0-PPF+CF1 20.00 8.00
M1 0-PPF+CF2 17.00 6.80 6.80
0-PPF+CF3 14.00 5.60
20% Fly-ash
20-PPF+CF1 29.00 11.60
M2 20-PPF+CF2 27.00 10.80 10.67
20-PPF+CF3 24.00 9.60
30% Fly-ash
30-PPF+CF1 21.00 11.03
M2 30-PPF+CF2 22.00 11.81 11.94
30-PPF+CF3 23.00 12.97

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.3.1 Flexural Test on Mono and Hybrid Fiber Beams:

Table 5.14 Flexural Test on Mono and Hybrid FRC Beams

Percentage Percentage
increase of increase of
0% Fly-ash, 20% Fly-ash, 30% Fly-ash, compressive
AVG VALUES compressive
N/mm2 N/mm2 N/mm2 strength for
strength for
20% fly-ash (%) 30% fly-ash (%)
PPF 6.40 7.60 10.31 18.75 61.09
PPF+CF 6.80 10.60 11.94 55.88 75.59

Flexural Strength of Beams

14.00
11.94
12.00
Flexural Strength, N/mm2

10.60 10.31
10.00
7.60
8.00 6.80
6.40
6.00

4.00

2.00

0.00
0% Fly-ash 20% Fly-ash 30% Fly-ash

PPF PPF+CF

Fig.5.2 Graphical representation for flexural strength

➢ Flexure strength test results showed that the addition of fly ash had a positive impact on
the flexure strength of mono FRC (PPF-1%). At 20% fly ash replacement showed 18.75%
increase in strength, while at 30% replacement resulted in a more substantial increase of
61.09%, compared to the mix without fly ash.
➢ The effect of fly ash on hybrid FRC (PPF-0.5% + CF-0.5%) followed a similar pattern.
The incorporation of 20% fly ash resulted in a 55.88% improvement in shear strength and
30% fly ash yielded a higher increase of 75.59% shear strength as compared to the mix
without fly ash.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.4 Shear Strength of Shear Specimens:

Table 5.15 Shear test on mono FRC beams

Shear test on mono FRC shear cubes

Avg.
Mix Design Specimen Failure Strength
Strength
(M30) Designation Load (kN) (N/mm2)
(N/mm2)
0% Fly-ash
0-PPF1 189.00 12.11
M1 0-PPF2 218.00 13.72 13.04
0-PPF3 247.00 13.28
20% Fly-ash
20-PPF1 239.00 13.28
M2 20-PPF2 229.00 12.72 12.72
20-PPF3 219.00 12.17
30% Fly-ash
30-PPF1 267.00 14.83
M2 30-PPF2 269.00 14.94 14.98
30-PPF3 273.00 15.17

Table 5.16 Shear test on hybrid FRC cubes

Shear test on hybrid FRC shear cubes

Avg.
Mix Design Specimen Failure Strength
Strength
(M30) Designation Load (kN) (N/mm2)
(N/mm2)
0% Fly-ash
0-PPF+CF1 234.00 13.00
M1 0-PPF+CF2 237.00 13.17 13.15
0-PPF+CF3 239.00 13.28
20% Fly-ash
20-PPF+CF1 252.00 14.00
M2 20-PPF+CF2 248.00 13.78 13.78
20-PPF+CF3 244.00 13.56
30% Fly-ash
30-PPF+CF1 287.00 15.94
M2 30-PPF+CF2 296.00 16.44 16.31
30-PPF+CF3 298.00 16.56

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.4.1 Shear test on mono and hybrid fiber shear cubes:

Table 5.17 Shear test on mono and hybrid FRC shear cubes

Percentage Percentage
increase of increase of
0% Fly-ash, 20% Fly-ash, 30% Fly-ash,
AVG VALUES compressive compressive
N/mm2 N/mm2 N/mm2
strength for strength for
20% fly-ash (%) 30% fly-ash (%)
PPF 12.11 12.72 14.98 5.04 23.70
PPF+CF 13.14 13.78 16.31 4.87 24.03

Shear Strength of Shear Specimen

18.00 16.31
16.00 14.98
13.78
Shear Strength, N/mm2

14.00 13.15 12.72

12.11
12.00
10.00
8.00
6.00
4.00
2.00
0.00
0% Fly-ash 20% Fly-ash 30% Fly-ash

PPF PPF+CF

Fig.5.3 Graphical representation for shear strength

➢ Shear strength test results showed that the addition of fly ash had a positive impact on the
shear strength of mono FRC (PPF-1%). At 20% fly ash replacement showed 5.04% increase
in strength, while at 30% replacement resulted in a more substantial increase of 23.7%,
compared to the mix without fly ash.
➢ The effect of fly ash on hybrid FRC (PPF-0.5% + CF-0.5%) followed a similar pattern. The
incorporation of 20% fly ash resulted in a 4.79% improvement in shear strength and 30% fly
ash yielded a higher increase of 24.03% shear strength as compared to the mix without fly
ash.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

5.5 Sorptivity Test on Specimen:

5.5.1 For mono FRC specimens:

Table 5.18 Sorptivity test for mono FRC specimens

Sorptivity test for mono FRC (PPF)

Time(t) 10mins 20mins 30mins 40mins 50mins 60mins 70mins 80mins
0% Fly-ash 35.75 47.00 54.25 58.75 64.00 66.00 66.25 66.25
S=i/√t 4.00 5.25 6.07 6.57 7.16 7.38 7.41 7.41
20%Fly- ash 43.25 52.50 57.75 61.25 66.75 69.30 70.25 70.25
S=i/√t 4.84 5.87 6.46 6.85 7.46 7.75 7.85 7.85
30% Fly-ash 48.00 54.00 59.75 63.25 67.50 70.75 71.25 71.25
S=i/√t 5.37 6.04 6.68 7.07 7.55 7.91 7.97 7.97

Table 5.19 Sorptivity Calculation

Time(t) S=i/√t
0% Fly-ash 7.41
20%Fly- ash 7.85
30% Fly-ash 7.97

SORPTIVITY TEST FOR MONO FRC (PPF)

S=i/√t
8.20
7.97
8.00 7.85
7.80
Sorptivity (S)

7.60
7.41
7.40

7.20

7.00
0% Fly-ash 20%Fly- ash 30% Fly-ash

Fig.5.4 Graphical Representation for Sorptivity Test for Mono FRC

5.5.2 Sorptivity values for mono FRC specimens with different proportions:
Table 5.20 Sorptivity test for mono FRC specimens of different proportions.

Sorptivity values at periodic intervals for Mono FRC (PPF) Specimens

Time(t) 10mins 20mins 30mins 40mins 50mins 60mins 70mins 80mins
0% Fly-ash 4.00 5.25 6.07 6.57 7.16 7.38 7.41 7.41
20%Fly- ash 4.84 5.87 6.46 6.85 7.46 7.75 7.85 7.85
30% Fly-ash 5.37 6.04 6.68 7.07 7.55 7.91 7.97 7.97

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

SORPTIVITY TEST
Sorptivity(S) v/s Time(t)
10.00

8.00
Sorptivity (S)
6.00

4.00

2.00

0.00
10mins 20mins 30mins 40mins 50mins 60mins 70mins 80mins
Time (t)
0% Fly-ash 20%Fly- ash 30% Fly-ash

Fig.5.5 Graphical Representation for Sorptivity Test w.r.t. (S) and (t) for Mono FRC

5.5.3 For Hybrid FRC Specimens:

Table 5.21 Sorptivity Test for Hybrid FRC Specimens

Sorptivity test for Hybrid FRC (PPF+CF)

Time(t) 10mins 20mins 30mins 40mins 50mins 60mins 70mins 80mins
0% Fly-ash 33.00 36.75 39.75 42.00 46.50 49.75 52.75 57.25
S=i/√t 3.69 4.11 4.44 4.70 5.20 5.56 5.90 6.40
20%Fly- ash 37.50 40.00 45.00 52.00 57.25 61.00 66.25 71.25
S=i/√t 4.19 4.47 5.03 5.81 6.40 6.82 7.41 7.97
30% Fly-ash 39.75 45.25 50.75 56.00 58.75 62.25 67.75 73.75
S=i/√t 4.44 5.06 5.67 6.26 6.57 6.96 7.57 8.25

Table 5.22 Sorptivity calculation

Time(t) S=i/√t
0% Fly-ash 6.40
20%Fly- ash 7.97
30% Fly-ash 8.25

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

SORPTIVITY TEST FOR HYBRID FRC (PPF+CF)

S=i/√t
10.00
7.97 8.25
8.00
6.40

Sorptivity (S)
6.00

4.00

2.00

0.00
0% Fly-ash 20%Fly- ash 30% Fly-ash

Fig.5.6 Graphical Representation for Sorptivity Test for Hybrid FRC

5.5.4 Sorptivity Values for Hybrid Specimens of Different Proportions:

Table 5.23 Sorptivity test for mono FRC specimens of different proportions

Sorptivity Values at periodic intervals for Hybrid FRC (PPF+CF) Specimens

Time(t) 10mins 20mins 30mins 40mins 50mins 60mins 70mins 80mins

0% Fly-ash 3.69 4.11 4.44 4.70 5.20 5.56 5.90 6.40

20%Fly- ash 4.19 4.47 5.03 5.81 6.40 6.82 7.41 7.97

30% Fly-ash 4.44 5.06 5.67 6.26 6.57 6.96 7.57 8.25

SORPTIVITY TEST
Sorptivity(S) v/s Time(t)
10.00

8.00
Sorptivity (S)

6.00

4.00

2.00

0.00
10mins 20mins 30mins 40mins 50mins 60mins 70mins 80mins
Time (t)
0% Fly-ash 20%Fly- ash 30% Fly-ash

Fig.5.7 Graphical representation for sorptivity test w.r.t. (S) and (t) for Hybrid FRC

➢ The sorptivity values for the 0%,20% and30% fly-ash mix was 7.41, 7.85 and 7.97 respectively
for Mono (PF-1%) FRC specimens.
➢ The sorptivity values for the 0%,20% and30% fly-ash mix was 6.40, 7.97 and 8.25 respectively
for Hybrid (PF-0.5% + CF-0.5%) FRC specimens.
➢ From the sorptivity test results, it was found that as the time goes on increasing, the sorptivity
values was found to be maximum for 30% Fly-ash Mixes.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

CHAPTER-6

CONCLUSION
➢ From the workability test results, it was found that as the percentage of fly-ash increases the
slump value decreases.

➢ The compressive strength results for 30% cement replacement with fly-ash was found to be
40.92% for hybrid fibers mix and 18.21% for mono fiber mix, when compared with reference
mix (0% Fly- Ash).

➢ The flexural strength results for 30% cement replacement with fly-ash was found to be
75.59% for hybrid fibers mix and 61.09% for mono fiber mix, when compared with reference
mix (0% Fly- Ash).

➢ The shear strength results for 30% cement replacement with fly-ash was found to be 24.03%
for hybrid fibers mix and 23.7% for mono fiber mix, when compared with reference mix (0%
Fly- Ash).

➢ By the use of hybrid fiber, it was found that the strength characteristics got enhanced when
compared to reference mix and mono fiber mix in all type of cement replacement with fly-
ash.

➢ From the experimental results, it was found that as the time goes on increasing, the sorptivity
values was found to be maximum for 30% fly-ash mixes.

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 Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

CHAPTER-7

FUTURE WORK SCOPE

Building upon the findings of this study, future research on fly ash and fiber-reinforced concrete
(FRC) could explore several promising avenues:

➢ Optimizing Fiber Combinations: Explore different fiber types (steel, glass, natural), ratios,
lengths, and orientations in hybrid combinations to maximize strength, workability, and
durability for specific applications.
➢ Durability Studies: Investigate water permeability, chloride ion penetration, carbonation
resistance, freeze-thaw resistance, and long-term strength under various conditions.
➢ Microstructural Analysis: Employ advanced techniques to understand the fibre-matrix
interaction and optimize mix design at the micro level.
➢ Cost-Effectiveness Analysis: Analyse initial costs (materials, labour) balanced against long-
term benefits (reduced maintenance) of FRC.
➢ Fire Resistance Evaluation: Assess the fire performance of FRC, considering fly ash as a heat
sink and different fiber types for high melting points.
➢ Self-Healing Concrete: Explore incorporating mechanisms like microcapsules to promote
crack closure and improve long-term performance.
➢ Sustainable Applications: Promote the use of FRC in pavements, bridge decks, and buildings
to reduce environmental impact through waste utilization (fly ash) and potentially lower
maintenance needs.
➢ Effect of Temperature Variations: Evaluate high-temperature behaviour (spalling resistance,
residual strength) and low-temperature behaviour (freeze-thaw resistance, de-icing salt impact)
of FRC.
➢ Durability Tests: Conduct water permeability, chloride ion penetration, carbonation resistance,
and sulphate attack tests to assess FRC's durability against various degradation mechanisms.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

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22. Hao Bao, Min Yu , Yin Chi , Yu Liu and Jianqiao Ye (2021). Performance evaluation of
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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

ANNEXURE

Fig. 6.1 Polypropylene fiber and Carbon fiber

Fig. 6.2 Addition of Cement to mechanical mixer

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.3 Measuring of fine and coarse aggregate.

Fig. 6.4 Addition of Polypropylene fiber to the mechanical mixer for dry mix.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.5 Addition of carbon fiber for hybrid mix and addition of water to wet mix.

Fig. 6.6 Addition of water to the concrete in mechanical mixer.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.7 Mold preparation for casting specimens.

Fig. 6.8 Compaction using mechanical viberator.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.9 Casted Specimens

Fig. 6.10 Specimens in curing tank.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.11 Compression Strength testing in CTM.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.12 Shear testing in CTM

Fig. 6.13 Shear plane crack. Fig. 6.14 Sorptivity testing.

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Strength Characteristics of Mono and Hybrid FRC using Fly-Ash 2023-24

Fig. 6.15 Tested Specimens.

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