CHAPTER 1

1.1 INTRODUCTION

1.2 WHY LIGHWEIGHT CONCRETE?

Lightweight concrete using foam agent is versatile building material with a simple production
method that is relatively inexpensive compared to autoclave aerated concrete. Lightweight
concrete compounds utilizing fly ash in a slurry mix is cheaper, and has less environmental
effects. It is produced in a variety of densities from 200 kg/m 3 to 1600 kg/m3 depending on the
application. Lighter density products may be cut into different sizes. While the product is
considered a form of concrete (with air bubbles replacing aggregate), its high thermal and
acoustical insulating qualities make it a very different application than conventional concrete.

1.3 COMPONENTS OF LIGHWEIGHT CONCRETE

Lightweight concrete is a versatile material that consists essentially of a foaming agent added
into the mix water that will produce discrete bubble cavities which is incorporated in cement
fly-ash paste.

1.3.1 Cement:Cement is a finely pulverized material which by itself is not a binder , but develops the binding
property as a result of hydration. Cement is called hydraulic when the hydration products are
stable in an aqueous environment. The most commonly hydraulic cement for making concrete is
Portland cement, which consists essentially of hydraulic calcium silicates.

1.3.2 Fly-ash:Fly ash is a byproduct from coal based thermal power plants . it has been generally considered
as a waste material in the past and disposal of which has posed numerous ecological and
environmental problems. However, recent researches have shown that the fly-ash as potential to
act as invaluable ingredient in cement and concrete if used within the framework of prescribe
1 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

specifications and quality system. The fly-ash is now considered as a resource material rather
than a waste in civil engineering and material science. In addition fly- ash can be gainfully used
for various other applications.
Fly-ash generation has already crossed 200 million tons per year and likely to increase to more
than 300 million tons by the year 2017. The utilization of such large quantity of fly-ash is a
herculean task which has be performed within various environmental protection laws. The
effective utilization of this resource material would not only minimize the disposal problem but
help in conservation of scarce minerals, reduce emission of green house gases and enhance
performance and durability of structure.

Beneficial properties of fly-ash:Fly-ash is used for the production of lightweight aggregates because of its lightweight nature.
Due to its resistance against variation in water content it has been used for clay flooring and
terracing. It has been used as a discoloring agent in dye effluent due to its adsorbing nature.
Because of its pozzolonic nature it has been used for replacement of cement in concrete,
manufacture of bricks, manufacture of cement, for cement replacement in manufacture of
concrete blocks and entrapping waste in its matrix. As fly-ash contains significant amount of
aluminum, it is used a raw material for aluminum recovery. It is used as an ingredient in grouting
applications because of its fineness and pozzolonic nature. In several geotechnical works such as
embankment, fill behind retaining walls, reclamation fill, dams etc. it has been used as a fill
material because of its low unit weight , low compressibility , faster rate of consolidation and
pozzolonic properties. It is used as sub grade material in roads due its pozzolonic property, good
drainage and resistance to variation in moisture content. Because of its high temperature
resistance and poor electrical conductivity it is used as a insulating material for underground high
tension wires. It is used for lightning mine fires, as a medium for combustion control on refuse
banks and as a refractory ingredient in the manufacture of iron and steel due to its resistance to
its high temperature.

1.3.3 Foaming Agent:Foaming agent is also called as air entraining agent. Air entraining agent are organic materials.
When foaming agent is added into the mix water it will produce discrete bubble cavities which

2 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

become incorporated in the cement paste. The properties of foam concrete are critically
dependent upon the quality of the foam.
There are two types of foaming agent :1. Synthetic foaming agent suitable for densities of 1000 kg/m3 and above.
2. Protein foaming agent suitable for densities from 400 kg/m3 to 1600 kg/m3.
Foams from protein based have a weight of around 80 gram / ltr. Protein based foaming agents
come from animal proteins out of horn, blood, bones of cows, pigs and other remainders of
animal carcasses. This leads not only to occasional variations in quality, due to the differing raw
materials used in different batches, but also to a very intense stench of such foaming agents.
Synthetic foams have a density of about 40 gram/ltr. Synthetic foaming agents are purely
chemical products. They are very stable at concrete densities above 1000 kg/m 3 and give good
strength. Their shelf life is about 1 year under sealed conditions. Synthetic foam has finer bubble
sizes compared to protein but they generally give lower strength foam concrete especially at
densities below 1000 kg/m3.

1.3.4 Fine aggregate:Fine aggregates generally consists of natural sand , m-sand or the combination of both. The only
fine sands suitable for concrete or mortar having particle sizes up to about 4mm and with an even
distribution of sizes should be used for lightweight concrete. This is mainly because coarser
aggregate might settle in the lightweight mix and lead to collapse of the foam during mixing. For
the practical reasons, most sands can only be used to produce lightweight concrete having a dry
density in excess of about 1200 kg/m3.
Manufactured sand is an alternative for river sand. Due to fast growing construction industry, the
demand for sand has increased tremendously, causing deficiency of suitable river sand in most
part of the world. Due to the depletion of the good quality river sand for the use of construction,
the use of m-sand has been increased. Another reason for use of m-sand is its availability and
transportation cost. Since this sand can be crushed from hard granite rocks, it can be readily
available at the near buy place, reducing the cost of construction from far off river bed. Thus the
cost of construction can be controlled by the use of m-sand as an alternative material for
construction. The other advantage of using m-sand, it can be dust free, the sizes of m-sand can be
controlled can be easily so that it needs the required grading for the given construction.

1.3.5 Water:3 | Page

ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Water is one of the important material for the foam concrete. Water with ph 6-8 which not tested
saline or brackish is suitable for use. Natural water that is slightly acidic is harmless, but water
containing humic or other organic acids may adversely affect the hardening of concrete. The
presence of algae in the mixing water will result in air entrainment with the absolute loss of
strength. Hardness of water does not affect the efficiency of air entraining admixtures. With too
much water, concrete will become a soapy mixture. Water is imperative for two reasons; one is to
hydrate the cement and second is to create a workable substance. Hydration of the cement is
necessary to form bonds in the aggregate which in turn give concrete its strength. Conversely the
presence of water filled spaces within the concrete is detrimental to its strength. Indications are
that concrete strength is directly related to porosity and water-cement ratio. This is shown by the
hydration process. As hydration of cement progresses, the volume of solids increases. This
volume in the space previously occupied by the un-hydrated cement. The increase in the solids
volume indicates the decrease in porosity. Porosity affects strength but strength itself is the result
of bonding. Developing bonds in mixtures with high water-cement mixtures is difficult due to the
distance between the particles. A high water-cement ratio means a mixture with high
porosity. Therefore high porosity means weaker bonds which in turn lead to lower strength. The
goal is to determine the approximate range of water-cement ratio that will yield high
compressive strength in the concrete.

1.4 LITERATURE REVIEW

Nagesh. Mustapure , H.Eramma (2014): The usage of Light Weight Foam Concrete
blocks gives a prospective solution to building construction industry. In this paper, an
experimental investigation on foam concrete blocks of varying grades of density is done. The
compressive strength of these light weight foam concrete blocks for 800 kg/m 3, 900 kg/m3, 1000
kg/m3 and 1100 kg/m3 is 2.6 N/mm2, 3.2 N/mm2, 3.8 N/mm2 and 5.8 N/mm2 for water curing.

4 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

The excellent insulating property of foam concrete is due to the great number of closed cavities
forming the multi-cellular structure.

Xianjun Tan (2014) : A type of ultra light foamed concrete , which can be used as a new
energy-conservation and environmental protection building material and is particularly suitable
for the thermal insulation engineering of building external walls, was produced. The influences
of different mixing amounts of fly ash, fly ash activator, water cement ratio and foaming agent
on compressive strength of foam concrete were reported . The experimental study indicated that
(1) the addition of fly ash reduced the strength of the foam concrete and that the appropriate
mixing amount of fly ash in this ultra light foam concrete system should not exceed 45% ; (2)
with the increasing of fly ash activator, the strength of the foam concrete sample is notably
enhanced and the appropriate mixing amount of fly ash activator is 2.5%. (3) the optimized
proportion of water cement ratio is 0.45, and the foam concrete that was produced according to
this proportion has relatively high compressive strength; (4) by increasing the mixing amount of
foaming agent, the compressive strength of the foam concrete notably decreases, and the optimal
mixing amount of foaming agent in this experiment is 3.5%.

Norlia Mohamad Ibrahim (2013): Performances of lightweight foamed concretes that are
made from partial substitution of waste clay brick as coarse aggregate has been investigated in
this study. The research aims were to identify the properties and characteristic of light weight
foamed concrete using waste clay brick as alternative materials to reduce the depletion of normal
coarse aggregate from granite. Four different percentages of concrete mixtures using new coarse
aggregate have been prepared that consist of 25% , 50% , 75% and 100% waste clay brick. Foam
was injected into concrete mixture to produce lightweight concrete with appropriate
proportions. The samples have undergone several testing including compression test, water
absorption test, workability test and density test. From the results obtained, lightweight concrete
that were

produced with 25% substitution of waste clay brick showed the highest compressive

strength of 25 Mpa with density of 1647 kg/m3.

5 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Nithyambigai. G (2015) : Scarcity of natural river sand because of environmental condition

need an alternative material. One such alternative is manufactured sand. The use of M-.sand in
concrete is desirable because of benefits such as useful disposal of a byproduct, reduction of
river sand consumption and increased strength. The use of fly ash in concrete is desirable
because of benefits such as increased workability, reduction of cement consumption and
decreased permeability. The use of fly ash leads to reduction in early strength of concrete but
there is an increase in long term strength. This paper investigates the strength of concrete mix at
28-day and 56-day age containing 0%, 25% and 50% of fine aggregate by M-sand and 0%, 25%
and 50% of cementations materials by fly ash. The concurrent use of the two byproducts will
lead to a economic and environmental benefits. The present study attempts to investigate the
influence of partial replacement of fly ash for cement and M-.sand for fine aggregate on the
mechanical properties and compared with the conventional concrete.

Khalid. Ali. M. Gelim (2011) : This research investigates physical and mechanical
properties of fly ash foamed concrete. Fly ash was used as fine aggregate . Six series of fly ash
foamed

concrete foe target densities (1000, 1100,1200,1300,1400 and 1500 kg/m 3) with

constant cement to fly ash ratio (1:1.5) and cement to water ratio (1:0.65) by weight were
prepared and tested. The findings from this project are very encouraging towards the use of fly
ash foamed concrete density of 1100 and 1200 kg/m3 in block application due to its compressive
strength (3.7-6.7 Mpa) whereas density of 1300, 1400 and 1500 kg/m 3 in structural application
due to its high compressive strength (10-18.8 MPa) and moderate water absorption that was
below 10%.

1.4 OBJECTIVE, SCOPE AND METHODOLOGY

1.4.1 OBJECTIVE
To produce lightweight concrete blocks by incorporating foam.

6 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

 To determine the compressive strength of lightweight foamed concrete with different

percentages of GGBS, M-sand as fly-ash replacement.
To develop high strength lightweight foamed concrete.

To develop cost-effective and low density lightweight masonry unit.

1.4.2 SCOPE
In this study, the lightweight foamed concrete were produced to determine the compressive
strength and density using different percentage of GGBS, M-sand, as fly-ash replacement. The
percentage of GGBS, M-sand as fly-ash replacement by total weight of cement and fly-ash such
as 0%, 5%,10%,15%. GGBS or M-sand is mixed with cement, fly-ash, water, and foam agent.
The density of lightweight foamed concrete must be obtained is less than 1000 kg/m 3 with mix
proportion ratio 1:1 comprises of cement to water ratio 0.5. Otherwise, the lightweight foamed
concrete without GGBS, M-sand replacement was design as a control mix.
50 cubes concrete were prepared to be test on compressive strength and density. Minimum three
test samples will be prepared for each parameter and the sample must accordance to 0%, 5%,
10%, 15%. For cubes have dimensions 150mm x 150mm respectively. All the specimens were
tested after curing at 7, 14, 28 days.
After the specimens matured at the followed curing days, the compressive strength and density
was determined in the laboratory.

1.4.3 METHODOLOGY
Lightweight concrete blocks are prepared using cement, fly-ash, foaming agent and water.
Suitable trial mixes are done with partial replacement of fly-ash with GGBS and M-sand to

7 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

achieve good compressive strength with various proportions of 0%, 5%, 10%, 15%. The design
mix proportion adopted is 1:1 and water-cement ratio of 0.50 is used.

EXPERIMENTAL STUDIES
1. Experimental tests were conducted to determine the chemical properties of cement and
fly-ash.
2. Density of lightweight masonry units was determined.
3. Compressive strength was determined for all the trial mixes.
4. Established relationship between compressive strength and density with suitable intervals.

CHAPTER 2
CHARACTERISTICS OF MATERIALS
8 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

2.1 INTRODUCTION
The strength and elastic properties of concrete block masonry are influenced by the individual
properties of the concrete blocks and the mortar. Characterization of the concrete block, mortar
and compressive strength of the concrete block masonry prisms are attempted in this study.
Compressive strength, characteristics of mortar, concrete block and masonry are obtained by
conducting experiments.

PRELIMINARY INVESTIGATION OF MATERIALS USED FOR

PREPARING LIGHTWEIGHT CONCRETE MASONRY UNITS
Cement
Ordinary Portland cement of 43grade conforming to Indian standards IS 8112: 1989 is used in
this investigation
Table 1 Properties of Cement
Sl
No
1
2
3
4
5
6

Properties

Result

Specific surface area

Normal consistency
Initial setting time
Final setting time
Specific gravity
Density

343 m2/kg
29%
122 minutes
230 minutes
3.15
979.7 kg/m3

Manufactured Sand
M-Sand plays an important role as a component in the production of concrete. M-sand
conforming to zone as per IS: 383-1970 is used for experiment after washing it with water.

9 | Page
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Table 2 Properties of M-sand

Sl No

Properties

Result

Bulk Density

1419 kg/m3

Specific gravity

2.62

Water absorption

2.5%

Fine modulus

2.1%

Surface texture

Smooth

Sieve analysis

Zone-

Fly ash of paper industry

Fly ash obtained from the paper mill. For the present study fly ash was obtained from a paper
mill in Najangudu, Mysore, and Karnataka, India. Tests on fly ash were conducted to determine
the physical properties such as specific gravity and consistency.

Specific gravity of fly-ash using specific gravity bottle:

Weight of empty bottle

W1 = 26.23 g

Weight of bottle + fly-ash

W2 = 31.40 g

Weight of bottle + fly-ash + keroseneW3 = 67.68 g

Weight of bottle + kerosene

W4 = 64.35 g

Specific gravity of kerosene = 0.79

Specific gravity of fly-ash

= [(W2-W1) / {(W2-W1) - (W3-W4)}] x 0.79

Result: Specific gravity of fly-ash = 2.22

Normal consistency of fly ash:

SL
No.
1

Mineral
Admixture

Depth of
penetration
mm

136.67

20

430

143.33

28

450

150.00

34

Weight of
water, gm

300

410

10 | P a g e
ENGINEERING,
NIE, MYSORE 300
2
Fly-ash

% water by
weight of
filler

Weight of
filler, gm

300

DEPARTMENT OF CIVIL

Result: Standard consistency of the fly ash (P) = 150%

GGBS (Ground Granulated Blast Furnace Slag)

GGBS was obtained from thermal power plant, Raichur, Karnataka. Tests on ggbs was
conducted to determine its physical properties.

Specific gravity of ggbs using specific gravity bottle:

Weight of empty bottle

W1 = 26.23 g

Weight of bottle + ggbs

W2 =47.64 g

Weight of bottle + ggbs + kerosene

W3 =79.73g

Weight of bottle + kerosene

W4 = 64.35 g

Specific gravity of kerosene = 0.79

Specific gravity of ggbs

= [(W2-W1) / {(W2-W1) - (W3-W4)}] x 0.79

Result: Specific gravity of ggbs = 2.80

Foaming Agent
Foaming agent allows to produce lightweight concrete of density ranging from 400 to 1600
kg/m3. The foaming agent is protein, contains natural surfactants and organic raw materials.
For this reason it obtains a pleasant odor. Size of foam bubbles is 0.01-0.1mm (10-50 microns)
Stability is 0.5 to 2.0 hours depending upon the temperature. Necessary amount of foam depends
on the required density of constructional mixture of concrete.

11 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Protein foaming agent for our project was bought from Nano-Foam technology, Coimbatore,
Tamilnadu.
Directions to use For 1 m3 of concrete, 1liter foaming agent is mixed with 60parts of water
which produces about 12 liters of foam which in turn is mixed with the cement water paste in the
drum mixer.

12 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

CHAPTER 3
EXPERMENTAL STUDY ON LIGHTWEIGHT
CONCRETE MASONRY UNITS
3.1 INTRODUCTION
Lightweight foam concrete is a class of aerated concrete. Aerated concrete can be classified
according to the methods and agents used to introduce air in the concrete. Aerated concrete can
be produced by introducing air entraining agent, gas forming chemicals and foaming agents.
Concrete which is aerated using foaming agent is known as lightweight foamed concrete.
Foaming agent can be synthetic based or protein based.
The use of lightweight foamed concrete offer many benefits and advantageous particularly cost
saving, fast completion and easy application compared to other materials such as steel and
timber. Lightweight foam concrete is characterized by its low compressive strength and
high Insulation against heat and sound. The compressive strength and other functional properties
of lightweight foamed concrete are greatly influenced by the amount of air content introduced by
foaming agents.
The application of lightweight foamed concrete in civil engineering works is very broad as it can
be used in almost every parts of building from the superstructure right down to the sub-structure,
including wall panels and flooring. Any conventional panels or masonry units used for load and
non load bearing walls using normal concrete can be replaced directly by foam concrete panels
and units. Very low density lightweight foam concrete can be used as thermal and sound
insulation panels, filtering media and floating blocks for fishery purposes.
Lightweight foamed concrete can also be used to cast elements for architectural purposes,
pottery, void filling, trench reinstatement, foundation rising and swimming pool. In highway
construction, lightweight foamed concrete can be applied as soil filling for sub base, bridge
abutments and bridge embankment. It is worth noticing that the use of lightweight foamed
concrete is popular in other countries such as Europe, Japan and United Kingdom.
13 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

The objective of proportioning concrete mixes in case of lightweight foam concrete is to arrive at
the most economical and practical combinations of different ingredients to produce concrete that
will satisfy the performance requirements under specified conditions of use. An integral part of
concrete mix proportioning is the preparation of trial mixes and effect adjustments to such trials
to strike a balance between the requirements of placement, that is, workability and strength,
concomitantly satisfying durability requirements.

In particular following cases have been taken in the study.

Lightweight masonry units

Using cement and fly-ash of mix proportion (1:1)

Using cement , 95% fly-ash and 5% GGBS of mix proportion (1:1)
Using cement , 90% fly-ash and 10% GGBS of mix proportion (1:1)
Using cement , 80%fly-ash and 20% GGBS of mix proportion (1:1)
Using cement , 50% fly-ash and 50% GGBS of mix proportion (1:1)
Using cement , 95% fly-ash and 5% M-sand of proportion (1:1)
Using cement, 90% fly-ash and 10% M-sand of proportion(1:1)

3.2 MIX DESIGN

The mix design of proportioning of concrete has been done by using procedure
given in IS2185 (Part 4):2008. This standard (Part 4) covers the requirements of
lightweight masonry units produced using foaming agent and having density from
800 kg/m3 to 1800 kg/m3 and primarily used for the construction of load bearing
and non- load bearing walls.

3.2.1 Mix design of 1:1 cement and fly-ash

14 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Type of cement: OPC 43 Grade (Zuari)

Maximum water cement ratio: 0.50
Method of concrete placing: Pumping
Test data for material
Cement used: OPC 43 Grade (Zuari)
Specific gravity of cement:
Specific gravity of fly-ash: 2.22
Density of fly-ash: 435 kg/m3
Density of cement: 1060 kg/m3
Mix calculation
Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3
Cement =0.016875/2 = 0.0084375 m3
Fly-ash =0.016875/2 = 0.0084375 m3
Cement =0.0084375 x 1060 = 8.9437kg
Fly-ash =0.0084375 x 435 =3.67kg
Water = 0.5 x 12.613 =3.606kg

15 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of

foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.
Water for foaming agent: 1.0125 kg
Mix proportion for trials
Cement: 9kg
Fly-ash: 3.8kg
Water: 3.7 kg
Water for foaming agent: 1.1 kg
Foaming agent: 20 ml

16 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Sl.no.

Days

Density(kg/m3)

Compressive
strength
(N/mm2)

840

0.88

14

871

1.04

28

887

1.2

Table
3.2.1:
Test
results
for

3.2.2 Mix design of 1:1 cement with 5% replacement of GGBS for fly-ash
Type of cement: OPC 43 Grade (Zuari)
Maximum water cement ratio: 0.50

17 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Method of concrete placing: Pumping

Test data for material
Cement used: OPC 43 Grade (Zuari)
Specific gravity of cement:
Specific gravity of fly-ash: 2.22
Specific gravity of GGBS: 2.80
Density of fly-ash: 435 kg/m3
Density of cement: 1060 kg/m3
Density of GGBS: 951 kg/m3
Mix calculation
Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3
Cement =0.016875/2 = 0.0084375 m3
Fly-ash =0.0084375 x 95/100 =0.0080156 m3
GGBS = 0.0084375 x 5/100 =0.00421875 m3
Cement =0.0084375 x 1060 =8.9437kg
Fly-ash =0.0080156 x 435 =3.486kg
GGBS =0.00421875 x 951 =0.4kg
Water = 0.5 x 12.83 =6.415kg
18 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of

foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.
Water for foaming agent: 1.0125 kg

Mix proportion for trials

Cement: 9kg
Fly-ash: 3.5kg
GGBS: 0.5kg
Water: 6.5kg
Water for foaming agent: 1.1 kg
Foaming agent: 20 ml
Table 3.2.2: Test results

Sl.no

Days

Density(Kg/m3)

Compressive
Strength
(N/mm2)

19 | P a g e
ENGINEERING, NIE, MYSORE

975

DEPARTMENT OF CIVIL

0.8

14

1000

1.5

28

1050

2.22

3.2.3 Mix design of 1:1 cement with 10% replacement of GGBS for fly-ash
Type of cement: OPC 43 Grade (Zuari)
Maximum water cement ratio: 0.50
Method of concrete placing: Pumping
Test data for material
Cement used: OPC 43 Grade (Zuari)
Specific gravity of cement:
Specific gravity of fly-ash: 2.22
Specific gravity of GGBS: 2.80
Density of fly-ash: 435 kg/m3
Density of cement: 1060 kg/m3
Density of GGBS: 951 kg/m3
Mix calculation
20 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3

Cement =0.016875/2 = 0.0084375 m3
Fly-ash =0.0084375 x 90/100 =0.00759375 m3
GGBS = 0.0084375 x 10/100 =0.00084375 m3
Cement =0.0084375 x 1060 =8.9437kg
Fly-ash =0.00759375x 435 =3.303kg
GGBS =0.00084375 x 951 =0.8kg
Water = 0.5 x 13.046=6.523kg
Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of
foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.
Water for foaming agent: 1.0125 kg
Mix proportion for trials
Cement: 9kg
Fly-ash: 3.5kg
GGBS: 1kg
Water: 6.6kg
Water for foaming agent: 1.1 kg

21 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Foaming agent: 20 ml

Table 3.2.3: Test Results

Sl.no

Days

Density(Kg/m3)

Compressive
Strength
(N/mm2)

1450

10

14

1480

11.11

28

1500

12.4

3.2.4 Mix design of 1:1 cement with 20% replacement of GGBS for fly-ash
22 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Type of cement: OPC 43 Grade (Zuari)

Maximum water cement ratio: 0.50
Method of concrete placing: Pumping
Test data for material
Cement used: OPC 43 Grade (Zuari)
Specific gravity of cement:
Specific gravity of fly-ash: 2.22
Specific gravity of GGBS: 2.80
Density of fly-ash: 435 kg/m3
Density of cement: 1060 kg/m3
Density of GGBS: 951 kg/m3
Mix calculation
Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3
Cement =0.016875/2 = 0.0084375 m3
Fly-ash =0.0084375 x 80/100 =0.00675 m3
GGBS = 0.0084375 x 20/100 =0.0016875 m3
Cement =0.0084375 x 1060 =8.9437kg
Fly-ash =0.00675x 435 =2.94kg
23 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

GGBS =0.0016875 x 951 =1.605kg

Water = 0.5 x 13.488 =6.744kg
Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of
foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.
Water for foaming agent: 1.0125 kg

Mix proportion for trials

Cement: 9kg
Fly-ash: 3kg
GGBS: 1.7kg
Water: 6.8kg
Water for foaming agent: 1.1 kg
Foaming agent: 20 ml
Table 3.2.4: test results

Sl.no

Days

Density(Kg/m3)

Compressive
strength
(N/mm2)

24 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

1670

12.44

14

1680

16.88

28

1695

20.00

3.2.5 Mix design of 1:1 cement with 50% replacement of GGBS for fly-ash
Type of cement: OPC 43 Grade (Zuari)
Maximum water cement ratio: 0.50
Method of concrete placing: Pumping
Test data for material
Cement used: OPC 43 Grade (Zuari)
Specific gravity of cement:
Specific gravity of fly-ash: 2.22
Specific gravity of GGBS: 2.80
Density of fly-ash: 435 kg/m3

25 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Density of cement: 1060 kg/m3

Density of GGBS: 951 kg/m3
Mix calculation
Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3
Cement =0.016875/2 = 0.0084375 m3
Fly-ash =0.0084375 x 50/100 =0.00421875m3
GGBS = 0.0084375 x 50/100 =0.00421875 m3
Cement =0.0084375 x 1060 =8.9437kg
Fly-ash =0.00421875x 435 =1.835kg
GGBS =0.00421875 x 951 =4kg
Water = 0.5 x 14.778=7.389kg
Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of
foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.
Water for foaming agent: 1.0125 kg
Mix proportion for trials
Cement: 9kg
Fly-ash: 1.9kg

26 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

GGBS: 4kg
Water: 7.5kg
Water for foaming agent: 1.1 kg
Foaming agent: 20 ml

Table 3.2.5:Test Results

Sl.no

Days

Density(Kg/m3)

Compressive
strength
(N/mm2)

1831

16.8

14

1840

18.66

27 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

28

1854

24

3.2.6 Mix design of 1:1 cement with 5% replacement of M-sand for fly-ash
Type of cement: OPC 43 Grade (Zuari)
Maximum water cement ratio: 0.50
Method of concrete placing: Pumping
Test data for material
Cement used: OPC 43 Grade (Zuari)
Specific gravity of cement:
Specific gravity of fly-ash: 2.22
Specific gravity of M-sand: 2.80
Density of fly-ash: 435 kg/m3
Density of cement: 1060 kg/m3
Density of M-sand: 1497 kg/m3
Mix calculation
Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3
Cement =0.016875/2 = 0.0084375 m3
28 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Fly-ash =0.0084375 x 95/100 =0.0080156m3

M-sand = 0.0084375 x 5/100 =0.000421875 m3
Cement =0.0084375 x 1060 =8.9437kg
Fly-ash =0.0080156x 435 =3.486kg
M-Sand =0.000421875 x 1497 =0.6315kg
Water = 0.5 x 13.0612 =6.531kg
Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of
foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.
Water for foaming agent: 1.0125 kg

Mix proportion for trials

Cement: 9kg
Fly-ash: 3.5kg
M-sand: 0.7kg
Water: 6.6kg
Water for foaming agent: 1.1 kg

29 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Foaming agent: 20 ml
Table 3.2.6: Test results

Sl.no

Days

Density(kg/m3)

Compressive
Strength
(N/mm2)

1030

2.00

14

1100

2.20

28

1300

3.00

3.2.7 Mix design of 1:1 cement with 10% replacement of M-sand for fly-ash
Type of cement: OPC 43 Grade (Zuari)
Maximum water cement ratio: 0.50
Method of concrete placing: Pumping
Test data for material
Cement used: OPC 43 Grade (Zuari)
30 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Specific gravity of cement:

Specific gravity of fly-ash: 2.22
Specific gravity of M-sand: 2.80
Density of fly-ash: 435 kg/m3
Density of cement: 1060 kg/m3
Density of M-sand: 1497 kg/m3
Mix calculation
Cube size =0.15 x 0.15 x 0.15 x 5 =0.016875 m3
Cement =0.016875/2 = 0.0084375 m3
Fly-ash =0.0084375 x 90/100 =0.00759375m3
M-sand = 0.0084375 x 10/100 =0.00084375 m3
Cement =0.0084375 x 1060 =8.9437kg
Fly-ash =0.00759375x 435 =3.303kg
M-Sand =0.00084375x 1497 =1.263kg
Water = 0.5 x 13.510 =6.754kg
Foaming agent: For 1m3 of concrete 60 parts of water is added to 1 liter of
foaming agent which in turn produces 12 liter of foam.
So for 0.016875 m3 16.8ml of foaming agent is used.

31 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

Water for foaming agent: 1.0125 kg

Mix proportion for trials
Cement: 9kg
Fly-ash: 3.4kg
M-sand: 1.27kg
Water: 6.8kg
Water for foaming agent: 1.1 kg
Foaming agent: 20 ml

Table 3.2.7: Test results

Sl.no

Days

Density(kg/m3)

Compression
Strength
(N/mm2)

32 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL

1305

4.01

14

1327

5.77

28

1370

6.66

33 | P a g e
ENGINEERING, NIE, MYSORE

DEPARTMENT OF CIVIL