A MAJOR PROJECT

On

STUDY PROPERTIES OF LIGHT WEIGHT AGGREGATE

CONCRETE
A Project report submitted in partial fulfilment of the requirements for the award of the degree
of

BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

Submitted to

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY

Submitted by

MAROJU PAVAN KALYAN 177Y1A0121

Under the esteemed guidance of

Dr. M.SARAVANAN
Associate Professor

DEPARTMENT OF CIVIL ENGINEERING

2020 – 2021

i
 DEPARTMENT OF CIVIL ENGINEERING

CERTIFICATE

This is to certify that the project entitled ‘STUDY PROPERTIES OF LIGHT WEIGHT
AGGREGATE CONCRETE’ by MAROJU PAVAN KALYAN (177Y1A0121), in the partial
fulfilment of the requirements for the award of the Degree of Bachelor of Technology in Civil
Engineering of MARRI LAXMAN REDDY INSTITUTE OF TECHNOLOGY AND
MANAGEMENT, Dundigal, Hyderabad during the academic year (2020-21).

Project Guide Head of the Department

Dr.M.SARAVANAN Mr. K. MURALI, ME, (PhD)

Associate professor

EXTERNAL EXAMINAR Principal

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

ii
 DECLARATION OF CANDIDATE

I hereby declare that the matter embodied in the report of mini project entitled " STUDY
PROPERTIES OF LIGHT WEIGHT AGGREGATE CONCRETE ”is genuine research work
carried out by me under the guidance of Dr.M.SARAVANAN, Associate Professor, Department of
Civil Engineering, Marri Laxman Reddy Institute of Technology and Management, Dundigal,
Hyderabad.

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

MAROJU PAVAN KALYAN

iii
 ACKNOWLEDGEMENT
I express my indebtedness and gratitude to my guide Dr.M.SARAVANAN, Associate professor,
Department of Civil Engineering, Marri Laxman Reddy Institution of Technology and
Management for his guidance and care taken by him in helping me to complete the project work
successfully.

I express my sincere thanks to Mr K. MURALI, M.E, (Ph.D), Head of Civil Engineering

Department for his support and guidance for doing the project.

I am very much thankful to Dr K. VENKATESWARA REDDY, M. Tech., PhD, MISTE principal

of Marri Laxman Reddy Institute of Technology and Management for their encouragement and
cooperation to carry out this work.

I express sincere thanks to all the teaching staff of Department of Civil Engineering for providing
a great assistance in the accomplishment of my project.

I also express my thanks to all the non-teaching staff of Department of Civil Engineering for giving
all the support and suggestions to complete my project.

I am very much thankful to the management of Marri Laxman Reddy Institute of Technology
and Management for their encouragement and cooperation to carry out this work.

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 ABSTRACT

In this present experimental work, a attempt is made to study on the strength properties of structural
light weight concrete produced replacing coarse aggregate by blending light weight aggregates such
as Cinder and LECA for M20 grade of concrete. The light weight concrete is prepared by using
Cinder and LECA ( lightweight expanded clay aggregate ) as light weight aggregates which were
blended in various percentage proportions (0:100,50:50,100:0) and vice- versa by volume of concrete.
By using this, the properties such as compressive strength, split tensile strength and density are
studied by casting plain cube specimens of size 150 x150 x150mm and cylindrical moulds of
150x300mm. M20 grade light weight concrete with 50% Cinder and LECA 50% had an average
compressive strength of 23.35N/mm2 and split tensile strength of 3.77N/mm2. The Ground
Granulated Blast Furnace Slag (GGBFS) is used by replacing 20% of cement which enhanced the
compressive to 23.35N/mm2.

Keywords
Cinder, LECA (lightweight expanded clay aggregate), Compressive strength, Split tensile strength.

v
 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

CERTIFICATE ii
DECLARATION OF CANDIDATE iii
ACKNOWLEDGEMENT iv
ABSTRACT v
LIST OF TABLES ix
LIST OF FIGURES viii
LIST OF SYMBOLS AND ABBREVIATIONS ix

1. INTRODUCTION 1
1.1 Classification of light weight concrete 2
1.2 Types of light weight concrete 3
1.3 Advantages of light weight concrete 6
1.4 Disadvantages of light weight concrete 6
1.5 Applications of light weight concrete 7
1.6 Light weight concrete vs Normal concrete 7

2. LITERATURE REVIEW 8
3. OBJECTIVE 12
4. METHODOLOGY 13
5. MATERIALS USED AND PROPERTIES 14
5.1 Portland cement 14
5.2 Fine aggregate and coarse aggregate 14
5.3 Water 15
5.4 Cinder 16
5.5 LECA 16
5.6 GGBFS(ground granulated blast furnace slag) 16

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6. EXPERIMENTAL INVESTIGATIONS 18
6.1 Mix Proportions 18
6.2 Casting of concrete 19
6.3 Casting of concrete cubes 19
6.4 Casting of concrete cylinders 20
6.5 Curing 20

6.6 Tests on cement 21

6.6.1 Fineness test 21
6.6.2 Normal consistency test 22
6.6.3 Initial setting time test 23
6.6.4 Specific gravity test 24

6.7 Tests on fine aggregate 25

6.7.1 Specific gravity test 25
6.7.2 Sieve analysis 25
6.7.3 Bulking of sand 26

6.8 Tests on coarse aggregate 27

6.8.1 Specific gravity test 27
6.8.2 Sieve analysis 28

6.9 Tests on light weight aggregate 29

6.9.1 Specific gravity 29
6.9.2 Sieve analysis of light weight aggregate 30
6.9.3 Aggregate crushing value test 31
6.9.4 Water absorption test 32
6.9.5 Bulk density of light weight aggregate 34

6.10 Tests on fresh concrete 35

6.10.1 Slump cone test 35

6.11 Tests on hardened concrete 37

6.11.1 Compressive strength 37
6.11.2 Split tensile strength 38

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7. RESULTS AND DISCUSSION 39
7.1 Test results of light weight aggregate 39
7.2 Slump cone test 39
7.3 compressive strength test 40
7.4 split tensile test 40
7.5 Comparison between strengths of normal
aggregate concrete and light weight
aggregate concrete 43

8. CONCLUSIONS 44
REFERENCES 45

viii
 LIST OF FIGURES

FIG.NO. TITLE PAGE NO.

1 Ordinary portland cement 14
2 Fine aggregate 14
3 Coarse aggregate 15
4 Cinder 16
5 LECA 16
6 GGBFS 17
7 Casting of cubes 20
8 Casting of cylinders 20
9 Curing 21
10 Specific gravity bottle 24
11 Pycnometer 25
12 Slump test 36
13 Compressive strength test 37
14 Split tensile strength test 38

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 LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1.6.1 Light weight concrete vs Normal weight concrete 7

6.1.1 Mix proportions 18

6.6.2.1 Normal consistency test of cement 23

6.7.2.1 Sieve analysis of fine aggregate 26

6.8.2.1 Sieve analysis of coarse aggregate 28

6.9.2.1 Sieve analysis of light weight aggregate 30

7.2.1 Slump test of concrete 39

7.3.1 Compressive strength test of concrete 40

7.4.1 Split tensile strength test of concrete 40

7.5.1 Comparison between normal concrete and light weight

Concrete 43

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 LIST OF SYMBOLS AND ABBREVIATIONS

F.A - Fine aggregate

C.A - Coarse aggregate
F.C.K - Mean compressive strength
F’.C.K - Target mean strength
M.pa - Mega pascal
I.S - Indian standard
Kgf - Kilogram-formula
LECA - Light weight expanded
Clay aggregate
GGBFS - Ground granulated blast
Furnace slag
LWA - Light weight aggregate
LWAC - Light weight aggregate
concrete

xi
 CHAPTER-1

INTRODUCTION

Any structure ultimately transfers the load to the soil strata beneath; the increase in the shear
number of structure has increased the stress on mother earth. The demand for construction
space has increased many folds with increase in necessity of human beings. According to recent
survey, the population density in world is around 54 persons per sq km, but in India it is around
400 persons per sq km. so, the developing country like India is having land scarcity. Hence
vertical growth is preferred than horizontal growth, since more and more people are moving
into urban areas lead to lot of land crunch. This land crunch and load increase demands the use
of light weight structural concrete. The light weight structural concrete helps in decreasing load
as the density is reduced substantially from ranges of 2400kg/cubic meter to 1800kg/cubic
meter.Light weight structural concrete is an enhanced version of concrete, with emphasis on
decrease in density of concrete. When structural concerns require a minimum to the dead load,
light weight concrete is used. It is ideal for roof deck repairs, stair pan fill, elevated floor slabs
or over lays on existing floor decks .since it is light weighted it is ease in lifting and carrying
which is an important advantage of light weight concrete. It also offers slower temperature
transfer rates than standard concrete, resulting in improved insulation fact.Lightweight concrete
mixture is made with a lightweight coarse aggregate and sometimes a portion or entire fine aggregates
may be lightweight instead of normal aggregates. Structural lightweight concrete has an in-place density
(unit weight) on the order of 90 to 115 lb / ft³ (1440 to 1840 kg/m³).Normal weight concrete a density
in the range of 140 to 150 lb/ft³ (2240 to 2400 kg/m³). For structural applications the concrete strength
should be greater than 2500 psi (17.0 MPa).Lightweight aggregates used in structural lightweight
concrete are typically expanded shale, clay or slate materials that have been fired in a rotary kiln to
develop a porous structure. Other products such as air-cooled blast furnace slag are also used.There are
other classes of non-structural LWC with lower density made with other aggregate materials and higher
air voids in the cement paste matrix, such as in cellular concrete.The concrete whose density is
comparatively less than that of normal conventional concrete is termed as light weight concrete.
The composition of light weight concrete is similar to that of conventional concrete except the
use of light weight aggregates or combination of both light weight aggregates & normal
aggregates. In some cases the fine aggregates portion are replaced by light weight products.
The bond between the cement and aggregates is strong in case of light weight concrete when
compared to that of normal conventional concrete. With the increase of construction works,
there is an increase in demand of light weight concrete due to its low density & improved
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 strength. The cost of light weight concrete is expensive, it is not only due to cost of aggregates
but it is an integration of various costs like labor, placing, transportation, reinforcements
etc….For structural purposes the concrete should possess higher strength. Light weight
aggregates used for structural light weight concrete are generally expanded shale, slate, cinder,
pumice etc….The use of light weight aggregates concrete in structures offers many advantages
over the conventional normal weight concrete, including an increased strength weight ratio and
improved thermal and sound insulation and fire resistances properties [K.Dhir and
et.al,1984].In concrete construction field, the concrete represents a very large proportion of the
total load on the structure and there are clearly considerable advantages in reducing its density.
One of the ways to reduce the weight of a structure is the use of light weight aggregate concrete
[Mouli and Khelali 2008].Light weight aggregate concrete (LWAC) has been used successfully
for structural purposes for many years, because of their improved properties such as the
workability, strength, less dead load and resistance to freezing and thawing of light weight
concrete [V. Khonsari and et.al 2010]The features of light weight, concrete are higher strength
to weight ratio as compared with conventional concrete, enhanced in thermal and sound
insulation, reduced dead load in the structure result reduce structural elements and minimize
the steel – reinforcement [Jihad Hamad Mohammed and et.al.2014]Light weight concrete has
strength comparable to normal weight concrete, yet is typically 25 % to 35% lighter, structural
light weight concrete offer & design flexibility and substantial cost savings by providing less
dead load, improved seismic structural response, longer spans [Fatrizal Zulkarnain et. all in
2008]Light weight concrete has vast applications in various fields due to its low density. The
aim of experiment is to develop the light weight concrete for the mix design of conventional
concrete such as M20 by full replacement of the portion of coarse aggregates (granite) by
blending of light weight aggregates such as LECA & CINDER with different percentages &
thereby achieving the target strength with low density of concrete. The concrete which is thus
developed is then compared with the conventional M20 grade concrete & further the graphs
are obtained for the above comparison.

1.1 CLASSIFICATION OF LIGHT WEIGHT CONCRETE

It is convenient to classify the various types of lightweight concrete by their method of
production. These are:
1. By using porous lightweight aggregate of low apparent specific gravity, i.e. lower than 2.6.
This type of concrete is known as lightweight aggregate concrete.

2
2. By introducing large voids within the concrete or mortar mass; these voids should be clearly
distinguished from the extremely fine voids produced by air entrainment. This types of concrete
is variously knows as aerated, cellular, foamed or gas concrete.
3. By omitting the fine aggregate from the mix so that a large number of interstitial voids is
present; normal weight coarse aggregate is generally used. This concrete as no-fines concrete.
LWC can also be classified according to the purpose for which it is to be used: it can distinguish
between structural lightweight concrete (ASTM C 330-82a), concrete used in masonry units
(ASTM C 331-81), and insulating concrete (ASTM C 332-83).This classification of structural
lightweight concrete is based on a minimum strength: according to ASTM C 330-82a, the 28-
day cylinder compressive strength should not be less than 17 MPa (2500 psi).The density (unit
weight) of such concrete (determined in the dry state) should not exceed 1840 kg/m³ (115
lb/ft³), and is usually between 1400 and 1800 kg/m³ (85 and 110 lb/ft³). On the other hand,
masonry concrete generally has a density between 500 and 800 kg/m³ (30 and 50 lb/ft³) and a
strength between 7 and 14 MPa (1000 and 2000 psi).

1.2 TYPES OF LIGHT WEIGHT CONCRETE

1. Lightweight Aggregate Concrete
In the early 1950s, the use of lightweight concrete blocks was accepted in the UK for load
bearing inner leaf of cavity walls. Soon thereafter the development and production of new types
of artificial LWA (Lightweight aggregate) made it possible to introduce LWC of high strength,
suitable for structural work.
These advances encouraged the structural use of LWA concrete, particularly where the need to
reduce weight in a structure was in a structure was an important consideration for design or for
economy.
Listed below are several types of lightweight aggregates suitable for structural reinforced
concrete:-
1. Pumice – is used for reinforced concrete roof slab, mainly for industrial roofs in Germany.
2. Foamed Slag – was the first lightweight aggregate suitable for reinforced concrete that was
produced in large quantity in the UK.
3. Expanded Clays and Shales – capable of achieving sufficiently high strength for prestressed
concrete. Well established under the trade names of Aglite and LECA (UK), Haydite, Rocklite,
Gravelite and Aglite (USA).

3
4. Sintered Pulverised – fuel ash aggregate – is being used in the UK for a variety of structural
purposes and is being marketed under the trade name Lytag
2. Aerated Concrete
Aerated concrete has the lowest density, thermal conductivity and strength. Like timber it can
be sawn, screwed and nailed, but there are non-combustible. For works in-situ the usual
methods of aeration are by mixing in stabilized foam or by whipping air in with the aid of an
air entraining agent.
The precast products are usually made by the addition of about 0.2 percent aluminums powder
to the mix which reacts with alkaline substances in the binder forming hydrogen bubbles.Air-
cured aerated concrete is used where little strength is required e.g. roof screeds and pipe
lagging. Full strength development depends upon the reaction of lime with the siliceous
aggregates, and for the equal densities the strength of high pressure steam cured concrete is
about twice that of air-cured concrete, and shrinkage is only one third or less.Aerated concrete
is a lightweight, cellular material consisting of cement and/or lime and sand or other silicious
material. It is made by either a physical or a chemical process during which either air or gas is
introduced into a slurry, which generally contains no coarse material.Aerated concrete used as
a structural material is usually high-pressure steam-cured. It is thus factory-made and available
to the user in precast units only, for floors, walls and roofs. Blocks for laying in mortar or glue
are manufactured without any reinforcement.Larger units are reinforced with steel bars to resist
damage through transport, handling and superimposed loads. Autoclaved aerated concrete,
which was originally developed in Sweden in 1929, is now manufactured all over the world.
3. No Fines Concrete
The term no-fines concrete generally means concrete composed of cement and a coarse (9-
19mm) aggregate only (at least 95 percent should pass the 20mm BS sieve, not more than 10
percent should pass the 10mm BS sieve and nothing should pass the 5mm BS sieve), and the
product so formed has many uniformly distributed voids throughout its mass.No-fines concrete
is mainly used for load bearing, cast in situ external and internal wall, non load bearing wall
and under floor filling for solid ground floors (CP III: 1970, BSI). No-fines concrete was
introduced into the UK in 1923, when 50 houses were built in Edinburgh, followed a few years
later by 800 in Liverpool, Manchester and London.This description is applied to concrete which
contain only a single size 10mm to 20mm coarse aggregate (either a dense aggregate or a light
weight aggregate such as sintered PFA). The density is about two-third or three quarters that
of dense concrete made with the same aggregates.No-fines concrete is almost always cast in

4
 situ mainly as load bearing and non load bearing walls including in filling walls, in framed
structures, but sometimes as filling below solids ground floors and for roof screeds.No-fines
concrete is thus an agglomeration of coarse aggregate particles, each surrounded by a coating
of cement paste up to about 1·3 mm (0·05 in.) thick. There exist, therefore, large pores within
the body of the concrete which are responsible for its low strength, but their large size means
that no capillary movement of water can take place.Although the strength of no-fines concrete
is considerably lower than that of normal-weight concrete, this strength, coupled with the lower
dead load of the structure, is sufficient in buildings up to about 20 storeys high and in many
other applications.
Types of Lightweight Concrete Based on Density and Strength
LWC can be classified as :-
1. Low density concrete
2. Moderate strength concrete
3. Structural concrete
1. Low Density Concrete
These are employing chiefly for insulation purposes. With low unit weight, seldom exceeding
800 kg/m³, heat insulation value are high. Compressive strength are low, regarding from about
0.69 to 6.89 N/mm2.
2. Moderate Density Concrete
The use of these concrete requires a fair degree of compressive strength, and thus they fall
about midway between the structural and low density concrete. These are sometimes designed
as ‘fill’ concrete. Compressive strength are approximately 6.89 to 17.24 N/mm² and insulation
values are intermediate.
3. Structural Concrete
Concrete with full structural efficiency contain aggregates which fall on the other end of the
scale and which are generally made with expanded shale, clay, slates, slag, and fly-ash.
Minimum compressive strength is 17.24 N/mm².
Most structural LWC are capable of producing concrete with compressive strength in excess
of 34.47 N/mm².
Since the unit weight of structural LWC are considerably greater than those of low density
concrete, insulation efficiency is lower. However, thermal insulation values for structural LWC
are substantially better than NWC.

5
 Durability of Lightweight Concrete
Durability is defined ass the ability of a material to withstand the effect of its environment. In
a building material as chemical attack, physical stress, and mechanical assault:-
Chemical attack is as aggregate ground-water particularly sulfate, polluted air, and spillage of
reactive liquids LWC has no special resistant to these agencies: indeed, it is generally move
porous than the ordinary Portland cement. It is not recommended for use below damp-course.
A chemical aspects of durability is the stability of the material itself, particularly at the presence
of moisture.Physical stresses to which LWC is exposed are principally frost action and
shrinkage and temperature stresses. Stressing may be due to the drying shrinkage of the
concrete or to differential thermal movements between dissimilar materials or to other
phenomena of a similar nature. Drying shrinkage commonly causes cracking of LWC if
suitable precautions are not taken.Mechanical damage can result from abrasion or impact
excessive loading of flexural members. The lightest grades of LWC are relatively soft so that
they subject to some abrasion were they not for other reasons protected by rendering.

1.3 ADVANTAGES OF LIGHTWEIGHT CONCRETE:

1. This concrete reduces the dead load due to less density.
2. No segregation and capillary movement of water because of the absence of fine aggregate.
3. It has better insulation properties than conventional concrete.
4. It has good sound insulation.
5. Produce low-cost concrete due to lower cement content.
6. It is eco-friendly due to the clinker, fly ash, slag.
7. It has low drying shrinkage.
8. Also has excellent drainage properties due to its open texture.
9. It has low formwork pressure.

1.4 DISADVANTAGES OF LIGHTWEIGHT CONCRETE:

1. This concrete is susceptible to water content in the mixture.
2. Cement mixtures have difficulty in placing and finishing.
3. In some combinations, the porosity and angularity of the holes, the aggregates separate and
float towards the surface.
4. The mixing time is longer than conventional concrete to achieve proper mixing.

6
 1.5 APPLICATIONS OF LIGHT WEIGHT CONCRTE
1. Screeds and thickening for general purposes especially when such screeds or thickening and
weight to floors roofs and other structural members.
2. Screeds and walls where timber has to be attached by nailing.
3. Casting structural steel to protect its against fire and corrosion or as a covering for architectural
purposes.
4. Heat insulation on roofs.
5. Insulating water pipes.
6. Construction of partition walls and panel walls in frame structures.
7. Fixing bricks to receive nails from joinery, principally in domestic or domestic type
construction.
8. General insulation of walls.
9. Surface rendered for external walls of small houses.
10. It is also being used for reinforced concrete.

1.6 LIGHTWEIGHT CONCRETE VS. NORMAL WEIGHT CONCRETE:

Table : 1.6.1

Normal Weight Concrete Lightweight Concrete

A normal weight concrete is going to be about 140 to 150 pounds per A lightweight concrete is going to be
cubic foot about 90-115 pounds per cubic foot.

Lightweight concrete has higher

Normal weight concrete has lower water content.
water content.

Projects made with normal-weight concrete require additional LWC remains a cost-effective
materials for framing, cladding, and a steel reinforcement that building material especially for large
ultimately increasing overall costs. projects.

7
 CHAPTER-2

LITERATURE REVIEW

An exhaustive research has been carried out to study the various properties of lightweight
Concrete which are as follows :

[1] Yasar et.al. [6] have performed a study on the design of structural lightweight concrete
(SLWC) made with basaltic pumice (scoria) as aggregate and fly ash as mineral
admixtures that will provide an advantage of reduction in dead weight of a structure,
and to obtain a more economical and greener mixture with the use of fly ash. The
compressive and flexural tensile strengths of hardened concrete, the properties of fresh
concrete including density, and slump workability were measured. Laboratory
compressive and tensile strength tests results showed that SLWC can be produced by
the use of scoria. However, the use of fly ash seems to be necessary for the production
of cheaper and environment-friendly SLWC with the compressive and tensile strengths
similar to control SLWC containing only NPC. Results showed that SLWC has an
advantage of the reduction of the dead weight of the structure at an average of 20%
since the dry weight unit of NWC is about 2300 kg/m3.

[2] H. Al-Khaiat and M.N. Haque [8] investigated the effect of initial curing on early
strength and physical properties of a lightweight concrete. They have used a high
strength structural lightweight concrete using Lytag LWA with a slump of about 100
mm, fresh unit weight of 1800 kg/m3 and 28 day cube compressive strength of
approximately 50 MPa. The specimens initially cured as; full curing, 1day curing, 3
day curing and 7 day curing. According to test results the compressive strengths of
SLWC seems to be less sensitive to lack of curing than the NWC, at least in the first
month of exposure. However, lack of curing seems to affect long-term strength
development of SLWC.

[3] Khandaker M. Anwar Hossain [10] carried out an suitability of using volcanic
pumice (VP) as investigation cement replacement material and as coarse aggregate in
lightweight concrete production. Tests were conducted on cement by replacing 0% to
25% of cement by weight and on concrete by replacing 0% to 100% of coarse aggregate

8
 by volume. The properties of volcanic pumice concrete (VPC) using different
percentages of volcanic pumice aggregate (VPA) were evaluated by conducting
comprehensive series of tests on workability, strength, drying shrinkage, surface
absorption and water permeability. The results showed that the VPC has sufficient
strength and adequate density to be accepted as structural lightweight concrete.
However, compared to control concrete, the VPC has lower modulus of elasticity and
has more permeability and initial surface absorption.

[4] T. Parhizkar et.al. [14] presented experimental investigation on the properties of

volcanic pumice lightweight aggregates concretes. To this end, two groups of
lightweight concretes (lightweight coarse with natural fine aggregates concrete and
lightweight coarse and fine aggregates concrete) are built and the physical/mechanical
and durability aspects of them are studied. The results of compressive strength, tensile
strength and drying shrinkage show that these lightweight concretes meet the
requirements of the structural lightweight concrete.

[5] P.C.Taylor[10] presently a professor at Wuhan University of Technology has said that
mineral admixtures affect the physical and mechanical properties of High Strength
Structural Light Concrete. Addition of Fly Ash enhances the compressive strength and
splitting tensile strength of HSSLC when FA was more than 20% in cementitious
materials, its 28 days compressive strength and splitting tensile strengths are less than
those of the concrete without FA. Addition of silica fume enhances the compressive
strength about 25% and splitting tensile strength also.

[6] Banthia, N. and Trottier,J.[1] conducted research on concrete reinforced with

deformed steel fibers and suggested that in lightweight fiber reinforced concrete the
addition of fibers produces an increase in compressive strength.

[7] Compione, G., et.al. [4] suggested that brittle nature of lightweight aggregate can be
overcome by increasing the ordinary confinement of transverse reinforcement and/or
by adding reinforcing fibers to the concrete matrix. Also they have suggested that the
presence of fibbers reduces material decay in the field of the strains exceeding that
corresponding to the peak value of strength.

9
[8] Campione G., Mindess S., and Zingone G. [2] suggested that in the case of normal
weight or light weight high strength concrete fibers in combination with traditional steel
reinforcements reduce the brittleness characterizing these advanced materials. Fibers
improve ductility of concrete and avoid congestion of secondary reinforcements
required in critical regions of structures designed in seismic zones. Lightweight
concrete, which was largely utilized for its nonstructural properties (as lagging or
soundproofing material), has also been employed more recently to make structural
elements, in particular in the field of precast concrete structures.

[9] Arunachalam et.al. [14] investigated the compressive and tensile strengths of
lightweight concrete (LWC) of density 1700 kg/m3 to 1800 kg/m3 with different
aluminium powder content using cube and cylinder specimens. Based on an earlier
investigation of the first two authors, cement to combined aggregate ratios of 1:6, 1:8,
and 1:10 have been selected. Both sand and quarry dust have been tried as fine
aggregate. Aluminium powder was added at 0.2% to 0.8% by weight of cement. The
strength related tests were carried out on hardened cement concrete at the age of 7 days
and 28 days. Hence, the results showed that 1:6 mix proportions gives more
compressive strength than the other two mix proportions in both the cases with quarry
dust and sand. However, compared with quarry dust mixes, sand mixes gave more
strength.Since lightweight concrete has the potential to produce commercial concrete
with many advantages, various experimental investigations and analysis have been
made by researchers to determine different properties and aspects of this new material.
However, its progress is hampered due to lack of knowledge in many developing
countries like India. To overcome this gap, there is a need to introduce the results drawn
from these researches in the standard code so that further experiments can be carried
out, as there is a lot of scope of development in construction industry.

[10] T. Divya Bhavana and Ropula Kishore Kumar, S. Nikhil, P. Sairamchander had
worked on the study of light weight concrete in which they concluded the compressive
strength of light weight concrete is lower than the ordinary conventional concrete and
from this compressive strength result, it is observed that as the percentage of ECA is
increasing the compressive and flexure strength is decreasing since, the density of

10
 concrete is reduced by addition of ECA. Also the workability of light weight concrete
is good when it is compared to the ordinary conventional concrete and this light weight
concrete has low thermal conductivity and has an ability to absorb sound.

[11] Miss Akshata A Mulgund and Dr. Dilip K Kulkarni had worked on the light weight
concrete in which they shown the comparison of both the densities of normal concrete
as well as light weight concrete. As per the density of light weight concrete is much
more lesser than normal concrete, so the lesser density of light weight concrete is helps
to reduce dead load of structure, increases the progress of building and it maintain the
economy of structure.

[12] Yasar et.al. have performed a study on the design of structural lightweight
concrete(SLWC) made with basaltic pumice (scoria) as aggregate and fly ash as mineral
admixtures that will provide an advantage of reduction in dead weight of a structure.
The compressive and flexural tensile strengths of hardened concrete, the properties of
fresh concrete including density and slump workability were measured. Laboratory
compressive and tensile strength tests results showed that SLWC can be produced by
the use of scoria. SLWC has an advantage of the reduction of the dead weight of the
structure at the average of 20% since the dry weight unit of NWC is about 2300 kg/m3
.

[13] T.Parhizkar et.al. presented experimental investigation on the properties of volcanic

pumice lightweight aggregates concretes. To this end, two groups of lightweight
concretes (lightweight coarse with natural fine aggregates concrete and lightweight
coarse and fine aggregates concrete) are built and the physical/mechanical and
durability aspects of them are studied. The results of compressive strength, tensile
strength and drying shrinkage show that these lightweight concretes meet the
requirements of the structural lightweight concrete.

11
 CHAPTER- 3

OBJECTIVES

The objectives of the project are finding out the properties of light weight aggregate,
experimental investigations on light weight aggregate concrete and blending the light weight
aggregate in various proportions to find out the optimum proportion that can be used to prepare
concrete mix and use for construction.

The main objectives are listed below:

 The objectives of project includes the collection of required materials i.e. cement, sand,
coarse aggregates, light weight aggregates , GGBFS from the various sources and
determining the properties of all the materials gathered.
 Designing the concrete mix proportions for replacement and addition of materials and
preparation of the concrete mix, moulding and curing.
 The testing of concrete includes Slump cone test for determining workability of
concrete in fresh state and compressive strength, split tensile test for determining the
strength of concrete in hardened state.
 To compare the compressive and tensile strengths of normal aggregate concrete and
light weight aggregate concrete.
 To learn the density differences between normal concrete and light weight concrete.
 The coarse aggregates are replaced by blending light weight aggregate cinder and
LECA in the ratio 0:100 , 50:50 and 100:0
 To find out the optimum proportion that can be used to prepare concrete mix and use
for construction.

12
 CHAPTER-4

METHODOLOGY

The below flow chart shows the methodology of the project:

Comparison Between
Strengths Of Normal
Identification Of Aggregate Concrete And Results And Discussion
Materials Light Weight Aggregate
Concrete

Tests On Hardened
Studying The Properties Conclusions
Concrete
Of Materials

Casting Of Moulds And

Testing Of Materials Curing

Calculation Of Mix
Proportions and mixing Tests On Fresh Concrete
of concrete

13
 CHAPTER-5
MATERIALS USED AND PROPERTIES
 Ordinary Portland Cement of 53 Grade cement conforming to IS:169-1989
 Fine aggregate and coarse aggregate conforming to IS: 2386-1963.
 Water
 Light weight aggregates ( cinder and LECA )
 GGBFS (Ground granulated blast furnace slag )

5.1 PORTLAND CEMENT

Portland cement is the most common type of cement in general use around the world as a basic
ingredient of concrete, mortar, stucco, and non-specialty grout. It was developed from other
types of hydraulic lime in England in the late 19th century by Joseph Aspdin, and usually
originates from limestone. It is a fine powder, produced by heating limestone and clay minerals
in a kiln to form clinker, grinding the clinker, and adding 2 to 3 percent of gypsum. Several
types of Portland cement are available. The most common, called ordinary Portland cement
(OPC).

Figure 1.Ordinary portland cement

5.2 FINE AGGREGATE AND COARSE AGGREGATE
Fine aggregate is the essential ingredient in concrete that consists of natural sand or crushed
stone. The quality and fine aggregate density strongly influence the hardened properties of the
concrete.

Figure 2.Fine aggregate

14
The concrete or mortar mixture can be made more durable, stronger and cheaper if you made
the selection of fine aggregate on basis of grading zone, particle shape and surface texture,
abrasion and skid resistance and absorption and surface.Coarse-grained aggregates will not
pass through a sieve with 4.75 mm openings. Those particles that are predominantly retained
on the 4.75 mm (No. 4) sieve and will pass through 3-inch screen are called coarse aggregate.
The coarser the aggregate, the more economical the mix. Larger pieces offer less surface area
of the particles than an equivalent volume of small pieces. Use of the largest permissible
maximum size of coarse aggregate permits a reduction in cement and water requirements.
Using aggregates larger than the maximum size of coarse aggregates permitted can result in
interlock and form arches or obstructions within a concrete form.

Figure 3.Coarse Aggregate

5.3 WATER

Water is one of the most important elements in construction and is required for the preparation
of mortar, mixing of cement concrete and for curing work etc. The quality of water used has a
direct impact on the strength of the motor and cement concrete in the construction work. The
water used for curing and mixing must be free from high quantities of alkalis, acid, oils, salt,
sugar, organic materials, vegetable growth, etc that might be deleterious to bricks, concrete or
iron. Impurities in water can cause metal corrosion, introduce unwanted silt and clay into the
concrete, adversely affect the hardening process of concrete and also reduce the strength by
even 25%. Thus the need to ensure the quality of water used during construction is vital.

15
5.4 CINDER:Cinder is a naturally occurring light weight rock of igneous origin. It is a
pyroclastic material which is similar to that of pumice and has many cavities with low density

Fig 4: Cinder Fig 5: LECA

Which can float in water. Cinder is generally black, brown or red in color depending on its
chemical composition. Now a days it is also called by name Scoria. Volcanic cinders are
uncemented, vitric, have bubble-like cavities, called vesicles, measure not less than 2.0 mm in
at least one dimension the apparent specific gravity is between 1.0 and 2.0. Figure 1 shows
the cinder used in study

5.5 LECA (light weight expanded clay aggregate)

It is abbreviated as LIGHT EXPANDED CLAY AGGREGATES. It is the special type of
aggregate which are formed by pyroclastic process in rotary kiln at very high temperature.
Since it is exposed to high temperature, the organic compounds burn, as a result the pellets
expand & form a honeycombed structure. Whereas the outside surface of each granule melts
and is sintered. The resulting ceramic pellets are lightweight, porous and have a high crushing
resistance. It is environmental friendly, entirely a natural product incorporating same benefits
as tile in brick form. LECA is non destructible, noncombustible & impervious to attack by dry-
rot, wet-rot & insects. Figure 2 shows the LECA used in study.
Before deciding any material to be used as aggregate it has to possess some standards set by
IS: 1343.As we are concerned with the mix design the basic tests were conducted the results
were determined.

5.6 GGBS
Ground-granulated blast-furnace slag (GGBS or GGBFS) is obtained by quenching molten
iron slag (a by-product of iron and steel-making) from a blast furnace in water or steam, to
produce a glassy, granular product that is then dried and ground into a fine powder. Ground-
granulated blast furnace slag is highly cementitious and high in CSH (calcium silicate hydrates)
which is a strength enhancing compound which improves the strength, durability and
16
appearance of the concrete.With the same cementitious material content (the total weight of
Portland cement CEM I plus GGBS), similar 28-day strengths to Portland cement CEM I will
normally be achieved when using up to 50% GGBS.At higher GGBS percentages the
cementitious content will need to be increased to achieve equivalent 28-day strength. The rate
of reaction and strength development of GGBS concrete is slower than equivalent concrete
made with Portland cement CEM I but continues at a significant rate for much longer (data
indicates continued development after many years). Typically the 7-day strength of a ggbs
concrete will be 55-65% of the 28-day strength compared to 70-80% for a similar CEM I
Portland cement concrete.The reduction in early-strength will be more noticeable at high
GGBS levels and low temperatures. Similarly low cement content concrete, kerb backing etc,
the reduction will be magnified.Under normal circumstances, the striking times for concretes
containing up to 50% GGBS, do not increase sufficiently to significantly affect the construction
programme. However, concretes with higher levels of GGBS will not always achieve sufficient
strength after one day to allow removal of vertical formwork, particularly at lower
temperatures, lower cementitious contents and in thinner sections.

Fig 6: GGBS

17
 CHAPTER-6
EXPERIMENTAL INVESTIGATIONS
6.1 MIX PROPORTIONS
The nominal mixes of fixed cement-aggregate ratio (by volume) vary widely in strength and
may result in under or over-rich mixes. For this reason, the minimum compressive strength has
been included in many specifications. These mixes are termed standard mixes. IS 456-2000
has designated the concrete mixes into a number of grades as M10, M15, M20, M25, M30,
M35 and M40. In this designation the letter M refers to the mix and the number to the specified
28 day cube strength of mix in N/mm2. The mixes of grades M10, M15, M20 and M25
correspond approximately to the mix proportions (1:3:6), (1:2:4), (1:1.5:3) and (1:1:2)
respectively.
Table : 6.1.1
(M20 GRADE CONCRETE)
1 Cement 306.4 kg/m3

2 GGBFS 76.6 kg/m3

3 Water 191.6 kg/m3

4 Fine aggregates 727 kg/m3

5 Coarse aggregates 1103 kg/m3

6 Water cement ratio 0.50

18
6.2 CASTING OF CONCRETE
Aggregates
The coarse aggregate was kept completely immersed in clean water for 24 hours and was gently
surface dried. It was then spread out and exposed to the atmosphere until it is completely
surface dry. For fine aggregate, the water was sprinkled then it was spread out and exposed to
the atmosphere until it appears to be completely surface dry.
Batching
Measuring the quantities of constituents of concrete required for the preparation of concrete
mix is called Batching. Weight batch method is used to measure the quantities. The quantities
of fine aggregate, Natural coarse aggregate, crushed ceramic waste, steel fiber, cement, water
and admixture for each batch were measured by a weighing balance according to the mix
proportions obtained by the mix design.
Mixing
The objective of mixing is to coat the surface of all aggregate particles with Cement paste and
to blend all the ingredients of concrete into a uniform mass. Though mixing of the materials is
essential for the production of uniform concrete. The mixing should ensure that the mass
becomes homogeneous, uniform in colour and consistency. At first dry mixing is necessary of
the uniform distribution of the fibre. Then the required amount of water is added to the mix.
Through mixing is necessary to get the consistent slurry of concrete. Admixture is added to the
mix at the later stage and after few minutes of mixing, the concrete becomes ready for placing.

6.3 CASTING OF CUBES

The size of cube specimen is 100X100X100mm. Each mould is provided with metal base plate
and with a capping plate. The mix design is based on strength criteria and durability criteria for
mild environmental exposure. The ratios by weight of cement, fine aggregates, coarse
aggregate, broken ceramic waste and steel fibre are obtained and mixed thoroughly in dry
condition. Then water required is added to the dry mix and mixed thoroughly till to obtain
uniform mixture. Super plasticizer is added to the mix to maintain the workability of fresh
concrete. The concrete is filled into the mould in 3 layers. Each layer is compacted with
tamping rod, for 25 blows each time. After the top layer has been compacted the surface of the
concrete is brought to the finished, level with the top of the mould, using a trowel. Six cubes
are casted in each batch of mix.

19
 Figure 7.Casting of cubes

6.4 CASTING OF CYLINDERS

Cylinder specimen of dimension 300mm height and 150mm diameter are casted along with
cubes. Before placing the concrete into the mould oil is applied on the inner and bottom surface
for easy removal of the specimen. The concrete is filled in the mould in layers. After placing
each layer, it is compacted with tamping rod, 25 blows each time. The tamping should be
uniform throughout the mould. Finally, top surface is smoothen using trowel.

Figure 8.casting of cylinders

6.5 CURING
Curing is the process of maintaining satisfactory moisture content and temperature in freshly
cast concrete for a definite period of time immediately following placement.It prevents or
replenishes the loss of moisture from the concrete. It maintains a favourable temperature for
hydration to occur for a definite period. Curing of Concrete is a method by which the concrete
is protected against loss of moisture required for hydration and kept within the recommended
temperature range. Curing will increase the strength and decrease the permeability of hardened
concrete. Curing is also helps in mitigating thermal and plastic cracks, which

20
 can severely impact durability of structures. A curing practice involves keeping the concrete
damp or moist until the hydration of concrete is complete and strength is attained. Curing of
concrete should begin soon after initial setting time of concrete or formwork/shuttering is
removed and must continue for a reasonable period of time as per the specified standards, for
the concrete to achieve its desired strength and durability.It is important to make sure an
uninterrupted hydration of PCC & RC after concrete is placed and finished in its position.
Uniform temperature ought to be maintained throughout the concrete-section depth to
avoid thermal shrinkage cracks.The casted moulds are dried for 24hrs. Then the moulds are
unmoulded. The cubes and cylinders were kept for curing in clean and potable water.

Figure 9.Curing

6.6 TESTING ON CEMENT

6.6.1 FINENESS OFCEMENT

AIM: To determine the fineness of the given sample of cement by sieving.
APPARATUS: IS-90 micron sieve conforming to IS:460-1965, standard balance, weights,
brush.
PROCEDURE:
 Weigh accurately 100 g of cement and place it on a standard 90 micron IS sieve.
 Break down any air-set lumps in the cement sample with fingers.
 Continuously sieve the sample giving circular motion for a period of15minutes.
 Weigh the residue left on the sieve. As per IS code the percentage residue should not exceed
10%.
OBSERVATIONS:
1) Weight of cement taken on the sieve =100gm
2) Weight of residue after sieving = 6gm

3) Percentage of fineness = ×100

21
 = ×100 =6%
RESULT: Fineness of given sample of cement is 6%

6.6.2 NORMAL CONSISTENCY OFCEMENT

(IS: 269 - 1989 and IS: 4031 - 1988 (Part 4))
AIM: To determine the quantity of water required to produce a cement paste of standard
consistency.
APPARATUS: Vicat’s apparatus (conforming to IS: 5513 - 1976) with plunger (10 mm in
diameter) balance, weights, gauging trowel.
PROCEDURE:
 Prepare a paste of weighed quantity of cement (400 grams) with a weighed quantity of potable
or distilled water, starting with 28% water of 400g of cement.
 Take care that the time of gauging is not less than 3 minutes, not more than 5 minutes and the
gauging shall be completed before setting occurs.
 The gauging time shall be counted from the time of adding the water to the dry cement until
commencing to fill the mould.
 Fill the vicat mould with this paste, the mould resting upon a non porous plate.
 After completely filling the mould, trim off the surface of the paste, making it in
levelwiththetopofthemould.Themouldmayslightlybeshakentoexpeltheair.
 Place the test block with the mould, together with the non-porous resting plate, under the rod
bearing the plunger (10mm diameter), lower the plunger gently to touch the surface of the test
block and quickly release, allowing it to penetrate into the paste.
 This operation shall be carried out immediately after filling the mould.
 Prepare trial pastes with varying percentages of water and test as described above until the
amount of water necessary for making the standard consistency as defined above is obtained.
 Express the amount of water as a percentage by weight of the dry cement.

22
 OBSERVATION
Table 6.6.2.1 Observations for normal consistency of cement
Percentage of water Quantity of water Vicat’s plunger
S.No added added in ml reading

1 28% 112 19

2 30% 120 6

RESULT: Normal consistency for the given sample of cement is 30%

6.6.3 INITIAL SETTINGTIME

AIM: To determine the initial setting time of cement as per IS: 4031 (part 5) -1988
APPARATUS:
 Vicat apparatus conforming toIS:5513-1976
 Balance, whose permissible variation at a load of 1000g should be+1.0g
 Gauging trowel conforming to IS:10086-1982
PROCEDURE:
● Prepare a cement paste by gauging the cement with 0.85 times the water required to give a
paste of standard consistency.
● Start a stop-watch, the moment water is added to the cement.
● Fill the vicat mould completely with the cement paste. The mould is placed on non-porous
plate and smooth off the surface of the paste making it level with the top of the mould. The
cement block thus prepared in the mould is the test block.
● Place the test block under the rod bearing the needle.
● Lower the needle gently in order to make contact with the surface of paste and quickly released
allowing it to penetrate the block
● Repeat the procedure till the needle fails to penetrate to a point 5.0±0.5mm measured from the

23
 bottom of the mould. The time taken between adding of water and above mentioned point is
the initial setting time.
OBSERVATIONS AND CALCULATIONS:
Weight of cement taken =400gms
Water required for normal consistency = 30% (120ml)
Weight of water taken for making specimen = 102ml
Initial setting time = 35minutes
LIMITATION
For ordinary Portland cement the initial setting time should not be less than 30 minutes and
final setting time not more than 10 hours.
RESULT
The initial setting time of given cement sample is 35 minutes.

6.6.4 SPECIFIC GRAVITY OF CEMENT

 Weight of empty specific gravity bottle (W1)= 26.5gm
 Weight of specific gravity bottle and cement (W2)= 36gm
 Weight of specific gravity bottle, cement and kerosene (W3)= 73.5gm
 Weight of specific gravity bottle and kerosene (W4)= 68gm
 Weight of specific gravity bottle and water (W5)= 79.5gm
𝑊4−𝑊1 68−26.5
Specific gravity of kerosene Sk= 𝑊5−𝑊1 = = 0.783
79.5−26.5
𝑊2−𝑊1 36−26.5
Specific gravity of cement= ((𝑊4−𝑊1)−(𝑊4−𝑊2))∗𝑆𝑘 = ((68−26.5)−(73.5−36))∗0.783

= 3.04

RESULT: Specific gravity of given sample of cement =3.04

Figure 10.Specific gravity bottle

24
 6.7 TESTING ON FINE AGGREGATES

6.7.1 SPECIFIC GRAVITY

AIM: To determine Specific gravity of sand using Pycnometer.
APPARATUS: Pycnometer, Tray, Weighing balance, stirrer.
MATERIALS USED: Fine aggregate or sand, distilled water.
 Weight of empty pycnometer (W1)= 500gm
 Weight of pycnometer and fine aggregate (W2)= 880gm
 Weight of pycnometer, fine aggregate and water (W3)= 1757gm
 Weight of pycnometer and water (W4)= 1520gm
𝑊2−𝑊1 880−500
 Specific gravity= ((𝑊2−𝑊1)−(𝑊3−𝑊4)) = ((880−500)−(1757−1520))

=2.65
RESULT: Hence the Specific Gravity of sand is calculated as2.65

Figure 11.Pycometer

6.7.2 SIEVE ANALYSIS OF SAND

AIM: To determine fineness modulus of sand
APPARATUS: The apparatus consists of eight different types of sieves i.e. 4.75mm, 2.36mm,
1.18mm, 600μ, 300μ, 150μ and 75μ sieve for fine aggregate.
MATERIALS USED: 500 gram sample of sand.
TEST PROCEDURE
● The sample shall be brought to an air-dried condition before weighing and sieving.
● Measure 3000 gram of the sand.
● Arrange sieve in descending order of size from the top.
● Put the sand in sieve 4.75mm, and shake for 10 minutes. Material shall not be forced through
the sieve by hand pressure.
● After 10 minutes stop the shaker and separate the sieve 4.75mm from the apparatus. Then
with the help of balance measure the weight of retained particles, note this weight in the
25
 table.
● Measure the weight of the particles retained in each sieve and notes them in the table.
● Calculate the percentage of weight retained on each sieve.
● Find the percentage of the weight which has passed through each sieve.

Table 6.7.2.1 Observations of sieve analysis of sand

Percentage
Sieve size (mm) Weight Weight retained Cumulative Cumulative
retained (gm) (gm) Percentage of percentage of
weight retained weight passed
4.75 22 0.6 0.6 99.4

2.36 32 0.76 1.32 98.68

1.18 144 3.6 4.92 95.08

600 µ 973 12.28 17.2 82.8

300 µ 2000 57.5 74.7 25.3

150 µ 1170 24.1 98.8 1.2

75 µ 480 1.2 99.99 0.01

Pan 5 0.033 100 0

Total 275

Finenessmodulus=275/100
=2.75

RESULT: Hence the Fineness modulus of sand is calculated as 2.75

6.7.3 BULKING OF SAND

AIM: To determine the moisture content at which bulking of sand occurs
APPARATUS: Measuring jar, weighing balance, mixing pan, trowel….etc
PRINCIPLE: Percentage of bulking of sand= (h1-h2)/h1 X100
Where, h1= level of dry sand
h2= level of wet sand

26
 PROCEDURE:
● Take a measuring jar and pour in the certain volume of sand, say up to the
heighth1.
● Now pour the same volume of water into the jar and stir the mixture of sand and
water.
● Keep the jar on the plain surface. Leave it for about 30minutes.
● It is observed that a first volume of sand decreases due to expulsion of
entrapped air and later volume slightly increases due to bulking action.
● Finally the final level of sand, say h2 is noted.
OBSERVATIONS AND CALCULATIONS:
Level of dry sand, h1 = 200ml
Level of wet sand, h2 = 180ml

Bulking percentage =

=11.11%
RESULT: Hence the percentage of bulking of sand is 11.11%

6.8 TESTING ON COARSE AGGREGATE

6.8.1 SPECIFIC GRAVITY

AIM: To determine Specific gravity of coarse aggregate using Pycnometer.
APPARATUS: Pycnometer, Tray, Weighing balance, stirrer.
MATERIALS USED: Coarse aggregate, distilled water.
PROCEDURE:
● Take a clean, dry pycnometer, and find its weight with its cap and washer(W1)
● Put about 500 g of coarse aggregate in the pycnometer and find its weight(W2)
● Fill the pycnometer and filled in coarse aggregate as in step2, with distilled water and measure
its weight (W3)
● Empty the pycnometer, clean it thoroughly, and fill it with clean water only to the hole of the
conical cap, and find its weight(W4)

27
● Repeat the same procedure at least for three differentsamples
OBSERVATIONS:
● Weight of empty pycnometer (W1)= 500gm
● Weight of pycnometer and coarse aggregate (W2)= 940gm
● Weight of pycnometer, coarse aggregate and water (W3)= 1800gm
● Weight of pycnometer and water (W4)= 1520gm
𝑊2−𝑊1 940−500
Specific gravity= ((𝑊2−𝑊1)−(𝑊3−𝑊4)) = ((940−500)−(1800−1520))

=2.75
RESULT: Hence the Specific Gravity of coarse aggregate is calculated as2.75

6.8.2 SEIVE ANALYSIS OF COARSE AGGREGATE

AIM: To determine the fineness modulus of given coarse aggregates.
APPARATUS: IS test sieves, square hole perforated plate 80mm, 40mm, 20mm, 12.5mm, and
4.75mm .Weighing balance (Sensitivity0.1 percent) sieve shaker, tray plates.
PROCEDURE:
 Take 5Kgs of coarse aggregate (nominal size 20mm) from the sample by quartering.
 Carry out sieving by hand, shake each sieve in order 80mm, 40mm, 20mm, 12.5mm, and
4.75mm for about 5minutes.
 The shaking is done with a varied motion backward and forward, left to right, circular,
clockwise and anticlockwise and with frequent jarring.
 So that material is kept moving over the sieve surface in frequently changing directions.
 Find the weight retained on each sieve taken in order
6.8.2.1 Observations of sieve analysis of coarse aggregate
Sisieve size (mm) Weight Cumulative Cumulative
retained (kg) Percentage of weight percentage of
retained weight passed

80 0 0 100

40 0.99 19.8 80.2

20 1.9 57.8 42.2

28
 12.5 1.43 86.4 13.6

4.75 0.68 100 0

Total 864

Fineness modulus =

= =8.64
RESULT: Hence the Fineness modulus of coarse aggregate is calculated as8.64

6.9 TESTS ON LIGHT WEIGHT AGGREGATE

6.9.1 SPECIFIC GRAVITY

AIM: To determine Specific gravity of coarse aggregate using Pycnometer.
APPARATUS: Pycnometer, Tray, Weighing balance, stirrer.
MATERIALS USED: Coarse aggregate, distilled water.
PROCEDURE:
● Take a clean, dry pycnometer, and find its weight with its cap and washer(W1)
● Put about 500 g of coarse aggregate in the pycnometer and find its weight(W2)
● Fill the pycnometer and filled in coarse aggregate as in step2, with distilled water and measure
its weight (W3)
● Empty the pycnometer, clean it thoroughly, and fill it with clean water only to the hole of the
conical cap, and find its weight(W4)
● Repeat the same procedure at least for three different sample
OBSERVATIONS:
 Weight of empty pycnometer (W1)= 500gm
 Weight of pycnometer and coarse aggregate (W2)= 940gm
 Weight of pycnometer, coarse aggregate and water (W3)= 1800gm
 Weight of pycnometer and water (W4)= 1520gm
W2−W1 940−500
Specific gravity= ((W2−W1)−(W3−W4)) = ((940−500)−(1800−1520))

29
 RESULT: Hence the Specific Gravity of light weight aggregate for cinder and LECA is found
as 1.52 and 0.51

6.9.2 SEIVE ANALYSIS OF LIGHT WEIGHT AGGREGATE

AIM: To determine the fineness modulus of given coarse aggregates.
APPARATUS: IS test sieves, square hole perforated plate 80mm, 40mm, 20mm, 12.5mm, and
4.75mm .Weighing balance (Sensitivity0.1 percent) sieve shaker, tray plates.
PROCEDURE:
 Take 5Kgs of coarse aggregate (nominal size 20mm) from the sample by quartering.
 Carry out sieving by hand, shake each sieve in order 80mm, 40mm, 20mm, 12.5mm, and
4.75mm for about 5minutes.
 The shaking is done with a varied motion backward and forward, left to right, circular,
clockwise and anticlockwise and with frequent jarring.
 So that material is kept moving over the sieve surface in frequently changing directions.
 Find the weight retained on each sieve taken in order
6.9.2.1 Observations of sieve analysis of coarse aggregate
Sieve size (mm) Weight Cumulative Percentage Cumulative
retained (kg) of weight retained percentage of
weight passed
80 0 0 100
40 0.99 19.8 80.2
20 1.9 57.8 42.2
12.5 1.43 86.4 13.6
4.75 0.68 100 0
Total 864

Fineness modulus =

=
RESULT: Hence the Fineness modulus of light weight aggregate for cinder and LECA is
found as 7.414 and 6.448

30
 6.9.3 AGGREGATE CRUSHING VALUE TEST ( IS : 2386 -PART - 4 )
INTRODUCTION:
The principal mechanical properties required in stones are (i) satisfactory resistance to crushing
under the roller during construction and (ii) adequate resistance to surface abrasion under
traffic. Aggregates used in road construction, should be strong enough to resist crushing under
traffic wheel loads. If the aggregates are weak, the stability of the pavement structure is likely
to be adversely affected. The strength of coarse aggregates is assessed by aggregates crushing
test. The aggregate crushing value provides a relative measure of resistance to crushing under
a gradually applied compressive load. To achieve a high quality of pavement, aggregate
possessing low aggregate crushing value should be preferred.
Obtect:
To determine the aggregate cmshing value by compressive testing machine.
Apparatus:
a) Steel cylinder with open ends, and internal diameter 152mm, square base plate, plunger having
a piston of diameter 150mm, with a hole provided across the stem of the plunger so that a rod
could be inserted for lifting or placing the plunger in the cylinder.
b) Cylindrical measure intemal diameter of 1 15mm and height 180mm.
c) Steel tamping rod with one rounded end, having a diameter of 16mm and length 450 to
600mm.
d) Balance of capacity 3 kg with accuracy up to lgm.
e) Compressive testing machine capable of applying load of 40 tomes, at a uniform rate of loading
of 4 tomes per minute.
Procedure:
The aggregate passing 12.5mm IS sieve and retained on 10mm IS sieve is selected for standard
test. The aggregate should be in surface dry condition before testing. The aggregate may be
dried by heating at a temperature 100C to 110C for a period of 4 hours and is tested after being
cooled to room temperature.The cylindrical measure is filled by the test sample of aggregate in
three layers of approximately equal depth, each layer being tamped 25 times by the rounded
end of the tamping rod. After the third layer is tamped, using the tamping rod as a straight edge
levels off the aggregate at the top of the cylindrical measure. About 6.5kg of aggregate is
required for preparing two test samples. The test sample thus taken is then weighed. The same
weight of the sample is taken in the repeat test.The cylinder of the test apparatus is placed in
position on the base plate; one third of the test sample is placed in this cylinder and tamped 25

31
 times by the tamping rod. Similarly, the other two parts of the test specimen are added, each
layer being subjected to 25 blows. The total depth of the material in the cylinder after tamping
shall however be 100mm. The surface of the aggregates is leveled and the plunger inserted so
that it rests on this surface in level position. The cylinder with the test sample and the plunger
in position is placed on compression testing machine. Load is then applied through the plunger
at a uniform rate of 4 tomes per minute until the total load is 40 tomes, and then the load is
released. Aggregates including the crushed portion are removed from the cylinder and sieved
on a 2.36mm IS sieve. The material, which passes this sieve, is collected.The above cmshing
test is repeated on second sample of the same weight in accordance with above test procedure.
Thus two tests are made for the same specimen for taking an average value.
Calculation:
The aggregate crushing value is defined, as a ratio of the weight of fines passing the specified
IS sieve to the total weight of the sample expressed as a percentage.
100 W2 Aggregate crushing value iThere,WI Totalweight of dry sample.
W2 Weight of the portion of cmshed material passing 2.36mm IS sieve.
Results:
The aggregate crushing value of the light weight aggregate cinder and LECA were found to be
37.52%; and 32.01%

6.9.4 WATER ABSORPTION TEST

INTRODUCTION:
Water absorption gives an idea of strength of aggregate. Aggregates having more water
absorption are more porous in nature and are generally considered unsuitable unless they are
found to be acceptable based on strength, impact and hardness tests.
Obtect:
To determine the specific gravity and water absolption of aggregates by perforated basket.
Apparatus:
 A wire basket of not more than 6.3mm mesh or a perforated container of convenient size with
thin wire hangers for suspending it from the balance.
 A thermostatically controlled oven to maintain temperature of 1000 to 1 1 OOC.
 A container for filling water and suspending the basket.
 An airtight container of capacity similar to that of the basket.

32
 A balance of capacity about 5 kg, to weigh accurate to 0.5 g, and of such a type and shape as
to permit weighing of the sample container when suspended in water.
 A shallow tray and two dry absorbent clothes, each not less than 750 X 450 mm.
Procedure:
About 2 kg of the aggregate sample is washed thoroughly to remove fines, drained and then
placed in the wire basket and immersed in distilled water at a temperature between 220 to 320C
with a cover of at least 50mm of water above the top of the basket. Immediately after immersion
the entrapped air is removed from the sample by lifting the basket containing it 25mm above
the base of the tank and allowing it to drop 25 times at the rate of about one drop per second.
The basket and the aggregate should remain completely immersed in water for a period of 24
+/- 0.5 hours afterwards.
The basket and the sample are then weighed while suspended in water at a temperature of 220
to 320C. In case it is necessary to transfer the basket and the sample to a different tank for
weighing, they should be jolted 25 times as described above in the new tank to remove air
before weighing. This weight is noted while suspended in water WI g. The basket and the
aggregate are then removed from water and allowed to drain for a few minutes, after which the
aggregates are transferred to one of the dry absorbent clothes. The empty basket is then retumed
to the tank of water, jolted 25 times and weight in water W2 g.The aggregates placed on the
absorbent clothes are surface dried till no further moisture could be removed by this cloth. Then
the aggregates are transfened to the second dry cloth spread in a single layer, covered and
allowed to dry for at least 10 minutes until the aggregates are completely surface dry. 10 to 60
minutes drying may be needed. The aggregates should not be exposed to the atmosphere, direct
sunhght or any other source of heat while surface drying. A gentle current of unheated air may
be used during the first ten minutes to accelerate the dlYing of aggregate surface. The surface
dried aggregate is then weighed W3 g. The aggregate is placed in a shallow tray and kept in an
oven maintained at a temperature of 1 for 24 hours. It is then removed from the oven, cooled
in an airtight container and weighed W4 g. At least two tests should be canied out, but not
concurrently.
Calculations:
Weight of saturated aggregate suspended in water with the basket
Weight of basket suspended in water
Weight of saturated aggregate in water
(W3-ws) g
Weight of saturated surface dlY aggregate in air

33
 Weight ofwater equal to the volume of the aggregate
(i) Water absorption percent by weight of water absorbed in terms oven dried weight of
aggregates.
(W3 — W4) 100

Results: The water absorption of light weight aggregates cinder and LECA were found to be
16.42% and 8.8%

6.9.5 BULK DENSITY OF LIGHT WEIGHT AGGREGATE

AIM: To determine the bulk density of given aggregates.

APPARATUS:
10 Kg capacity balance with weights, cylindrical containers of 1 litre and 5 litre capacities,
measuring jar of 1000ml capacity.
PROCEDURE:
1. Find the weight of the empty container W1.
2. Take coarse aggregate in the container up to approximately half of the container and find out
the weight W2.
3. Fill the container with water up to the level of the coarse aggregates so that all void space inside
the aggregate is filled with water. Find its weight W3.
4. Fill the container with water after emptying it from mix of coarse aggregate and water.
5. Water should be up to the mark, up to which coarse aggregate is filled. Find its weight W4
6. Repeat the same process for another trail by taking the aggregate up to the full of the container
and by filling the water up to same point.
OBSERVATIONS:
Sl. No Trail 1 Trail 2
1. Weight of empty container W1.
2. Weight of container with material W2.
3. Weight of container + material + water W3.
4. Weight of container + water W4.
i) Bulk density = W2 - W1 / (W4 - W1)

34
Results:
Cinder- Bulk density in Loose state % voids was 67.84% and Compacted state % voids was
59.76%

LECA- Bulk density in Loose state % voids was

79.59% and Compacted state % voids was 68.94%

6.10 TESTS CONDUCTED ON FRESH CONCRETE

6.10.1 SLUMP CONE TEST

This test is used extensively in site all over the world. The slump test does not measure the
workability of concrete, but the test is very useful in detecting variations in the uniformity of a
mix of given nominal proportions.
The slump test is done as prescribed by IS: 516.
The apparatus for conducting the slump test essential consists of a metallic mould in the form
of a cone having the internal dimensions asunder
Bottom diameter: 200 mm
Top diameter: 100 mm
The mould for slump is a frustum of a cone, 300 mm high. It is placed on a smooth surface
with the smaller opening at the top, and filled with concrete in three layers. Each layer is tamped
twenty five times with a standard 16 mm diameter steel rod, rounded at the end, and the top
surface is stricken off by means of sawing and rolling motion of the tamping rod. The mould
must be firmly fixed against its base during the entire operation; this is facilitated by handles
or foot-rests brazed to the mould. Immediately after filling, the cone is slowly lifted vertically
up, and the unsupported concrete will now slump – hence the name of the test. The difference
in level between the height of the mould and that of highest point of subsided concrete is
measured. This difference in height in mm is taken as slump of concrete. If instead of slumping
evenly all rounds as in a true slump one half of the cone slides down an Inclined plane, a shear
slump is said to have taken place and test should be replaced. If shear slump persists, as may
be the case with harsh mixes, this is an inclination of lack of cohesion in the mix.Mixes off
stiff consistency have a zero slump, so that in the rather by range, no variation can be detected
between mixes of different workability. Rich mixes behave satisfactorily, their slump being
sensitive to variations in workability however, in a lean mix a with a tendency to harshness, a

35
true slump can easily change to the shear type, or even to collapse and widely different values
of slump can be obtained in different samples from the same mix.Despite these limitations, the
slump test is very useful at the site to check on the batch or hour- to- hour variation in the
materials being fed into mixer, as increase in slump may mean, for instance, that the moisture
content of aggregate has unexpectedly increased; another cause would be a change in the
grading of the aggregates, such as a defiance of sand .too low and too high slump gives
immediate waning and enables the mixer operator to remedy the situation. This application of
the slump test as well as its simplicity is responsible for its widespread use. A mini slump test
was developed for the purpose of assessing the influence of various water- reducing admixtures
and super plasticizers on neat cement paste. The test may be useful for the specific purpose,
but it is important to remember that workability of concrete is affected also by factors other
than the flow properties of the constituent cement paste. The difference in level between the
height of the mould and that of highest point of subsided concrete is measured. This difference
in height in mm is taken as slump of concrete. If instead of slumping evenly all rounds as in a
true slump one half of the cone slides down an Inclined plane, a shear slump is said to have
taken place and test should be replaced. If shear slump persists, as may be the case with harsh
mixes, this is an inclination of lack of cohesion in the mix.Mixes off stiff consistency have a
zero slump, so that in the rather by range, no variation can be detected between mixes of
different workability. Rich mixes behave satisfactorily, their slump being sensitive to
variations in workability however, in a lean mix a with a tendency to harshness, a true slump
can easily change to the shear type, or even to collapse and widely different values of slump
can be obtained in different samples from the same mix.Despite these limitations, the slump
test is very useful at the site to check on the batch or hour- to- hour variation in the materials
being fed into mixer, as increase in slump may mean, for instance, that the moisture content of
aggregate has unexpectedly increased; another cause would be a change in the grading of the
aggregates, such as a defiance of sand.

Figure 12.Slump test

36
6.11 TESTS CONDUCTED ON HARDENED CONCRETE

6.11.1 COMPRESSIVE STRENGTH

Compressive strength of concrete is the Strength of hardened concrete measured by the
compression test. The compression strength of concrete is a measure of the concrete's ability
to resist loads which tend to compress it. It is measured by crushing concrete cube specimens
in compression testing machine.The compressive strength of concrete can be calculated by the
failure load divided with the cross sectional area resisting the load and reported in mega pascals
(MPa) in SI units. Concrete's compressive strength requirements can vary from 17 MPa for
residential concrete to 28 MPa and higher in commercial structures. Higher strengths up to and
exceeding 70 MPa are specified for certain applications.For cube test two types of specimens
either cubes of 150mm X 150mm X 150mm or 100mm X 100mm x 100mm depending upon
the size of aggregate are used. For most of the works cubical moulds of size 150mm x 150mm
x 150mm are commonly used.This concrete is poured in the mould and tempered properly so
as not to have any voids. After 24 hours these moulds are removed and test specimens are put
in water for curing.These specimens are tested by compression testing machine after 7 days
curing and 28 days curing. Load should be applied gradually till the Specimens fails. Load at
the failure divided by area of specimen gives the compressive strength of concrete.

Figure 13.Compressive strength testing machine

𝐿𝑜𝑎𝑑𝑎𝑡𝑤ℎ𝑖𝑐ℎ𝑐𝑝𝑒𝑐𝑖𝑚𝑒𝑛𝑓𝑎𝑖𝑙𝑠
Compressive strength of concrete= 𝐶𝑟𝑜𝑠𝑠𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑟𝑒𝑎𝑜𝑓𝑐𝑢𝑏𝑒

37
6.11.2 SPLIT TENSILE STRENGTH TEST
The tensile strength of concrete is one of the basic and important properties which greatly affect
the extent and size of cracking in structures.Moreover, the concrete is very weak in tension due
to its brittle nature. Hence it is not expected to resist the direct tension. So, concrete develops
cracks when tensile forces exceed its tensile strength.Therefore, it is necessary to determine the
tensile strength of concrete to determine the load at which the concrete members may crack.
Furthermore, splitting tensile strength test on concrete cylinder is a method to determine the
tensile strength of concrete.The test is carried out by placing a cylindrical specimen
horizontally between the loading surfaces of compression testing machine and the load is
applied until failure of cylinder, along its longitudinal direction.

Split tensile strength= Where

P = compressive load on the cylinder.
L=length of the cylinder
D= diameter of cylinder

Figure 14.Split tensile Strength testing machine

38
 CHAPTER-7
RESULTS AND DISCUSSION
WORKABILTY
The ideal concrete is the one which is workable in all conditions i.e., can prepared easily placed,
compacted and molded. In this project ceramic waste and steel fiber is added in concrete mix
and workability is tested by doing slump cone and compaction factor test. From the results
obtained, the addition of ceramic waste and steel fiber does not affect the workability of
concrete.

7.1 TEST RESULTS OF LIGHT WEIGHT AGGREGATE

Tests conducted on LECA were
 Specific gravity = 0.51
 Bulk density in Loose state % voids was 79.59% and Compacted state % voids was 68.94%;
 Aggregate crushing test was 37.52%
 Water absorption was 16.42%
 Fineness modulus was found to be 6.448.
Tests conducted on Cinder were
 Specific gravity = 1.52
 Bulk density in Loose state % voids was 67.84% and Compacted state % voids was 59.76%;
 Aggregate crushing test was 32.01%
 Water absorption was 8.8%
 Fineness modulus was found to be 7.414

7.2 SLUMP CONE TEST

The test was conducted for fresh concrete prepared before the molding process. Workability
Results obtained from slump cone test for M20 grade of concrete for replacement of light
weight aggregate in different proportions are listed below.
Light Weight
SL. Slump (mm)
Aggregate
No
% LECA %Cinder

1 0 100 27
2 50 50 53
3 100 0 37

39
7.3 COMPRESSION STRENGTH OF CUBES
The cubes of size 150 x 150 x 150mm were casted and tested for 7 days and 28 days testing of
specimens for each percentage after conducting the workability tests. The average compressive
strength are tabulated in Table 2
Table7.3.1: Average Compressive Strength
SL. Light Weight Density Avg Compressive
No Aggregate (kg/m3) Strength (N/mm2)

% LECA %Cinder 7 days 28 days

1 0 100 2325.92 17.560 24.910

2 50 50 1777.77 15.260 23.266

3 100 0 1454.81 13.208 21.018

7.4 SPLIT TENSILE TEST

Table 7.4.1: Average tensile strength
SL. Light Weight Slump (mm) Average Tensile

No Aggregate Strength (N/mm2)

% LECA %Cinder 7 days 28 days

1 0 100 27 2.73 3.64

2 50 50 53 2.53 3.77

3 100 0 37 2.34 3.59

40
The comparison of experimental results and analyzing were done in graphical way.

Analysis of slump results of fresh concrete mix: Here the slump test carried out for various
proportions of fresh concrete mixes of M20 grade are compared.

60 53
50
40 37

30 27
Slump

20
10
0
0 50 100
Aggregate proportion
Comparison of %Aggregate proportion V/S Slump(mm)

GRAPH 1: Comparison of %Aggregate proportion V/S Slump(mm)

Analysis of compressive strength of hardened concrete: Here the compressive strength of

various proportions of M20 for different curing periods such as 7 days and 28 days are analysed

Comparison of %Aggregate proportion V/S

Compressive strength
30
Compressive strength

24.91
25 23.266
21.018
20 17.56
15.26
15 13.208

10
5
0
0 50 100
% Aggregate proportion
7 days 28 days

GRAPH 2 : Comparison of %Aggregate proportion V/S Compressive strength

41
Analysis of split tensile strength results of hardened concrete: Here the split tensile
strength of various proportions of both M20 for different curing periods such as 7 days
and 28 days are analysed.

Comparison of %Aggregate proportion V/S Split

Tensile strength
4 3.64 3.77
3.59
3.5
Split tensile strength

3 2.73
2.53
2.5 2.34

2
1.5
1
0.5
0
0 50 100
% aggregate proportion

7 days 28 days

GRAPH 3: Comparison of %Aggregate proportion V/S Split Tensile strength

Based on the results of the experimental investigation carried out, 50% of cinder & 50% of
LECA has found to be optimum design mix for obtaining the designed concrete mix. In order
to improve the compressive strength, for the same mix the 20% of cement was replaced by
Ground Granulated Blast Furnace Slag which improved the compressive strength to
23.35N/mm2. The mix proportions and results are tabulated in Table 5 and 6 respectively.

42
7.5 Comparison Between Normal Concrete And Light Weight Concrete

Below table shows the strength differences between normal concrete and light weight concrete
tested after 7days and 28 days
Table : 7.5.1

Compressive Strength of Normal Compressive Strength of Light weight

Concrete (N/mm2) concrete (N/mm2)

7 days 28 days 7 days 28 days

15.54 28.62 15.26 23.34

15.05 28.28 15.87 23.26

14.96 28.05 15.69 23.45

43
 CHAPTER-8

CONCLUSIONS

1. Based on the results of the experimental investigation carried out and in scope of work
carried out, the conclusions are drawn.
2. Cinder and LECA can be used as a light weight aggregate in replacement of normal
coarse aggregate.
3. Increasing the percentage of light weight aggregate decreases the cubes weight from
8.5kg to 5.15kg. But simultaneously there was decreasing strength. Blending of
aggregates showed better performance in this case
4. The concrete mixes are blended in various proportions like ( 0:100 , 50:50 , 100:0 ) in
cinder and LECA.
5. 50% of cinder and 50% of LECA with 20% of GGBS replaced for cement gave a good
low weight structural concrete.
6. Cinder and LECA can be used as light weight aggregate in replacement of normal
coarse aggregate. M20 grade light weight concrete had an average compressive strength
of 23.35N/mm2 respectively which was almost nearer to the compressive strength of
normal aggregate concrete which was 28.31N/mm2.
7. The density of light weight aggregate concrete varied from 1750 to 1850 kg/mm3 which
were lesser than that of normal weight concrete having a density of 2651 kg/mm3.
8. There was significant cost reduction when compared to normal concrete. The batching
of concrete work is done in volume wise, 1kg of LECA replaced 3.5 kg of normal
aggregate by mass

44
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