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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15

CHAPTER - 1
INTRODUCTION

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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15

1. Introduction
1.1 General

The present day world is witnessing construction of very challenging and difficult
civil engineering structures. Researchers all over the world are attempting to develop low
density or lightweight concrete by using different admixtures in concrete up to certain
proportions

This Project deals with the development of Floating concrete by using lightweight
aggregate (Pumice stone) and Aluminum powder as an air entraining agent.

Floating concrete is made by introducing air or gas into concrete slurry, so that
when the mix sets and hardens, uniform cellular structure is formed. Thus it is a mixture
of water, cement and finely crushed sand. We mix fine powder of Aluminum to the slurry
and it reacts with the calcium hydroxide present in it thus producing hydrogen gas. This
hydrogen gas when contained in the slurry mix gives the cellular structure and thus makes
the concrete lighter than the conventional concrete.

Pumice stone is a lightweight aggregate of low specific gravity. It is a highly


porous material with a high water absorption percentage. In this we do not use the
conventional aggregate and replace it by the pumice stone.

1.2 Floating Concrete

Floating concrete can be defined as the concrete which can float on the water or
the concrete which has density less than or equal to density of water. It is one of the types
of lightweight concrete. Lightweight concrete includes expanding agents that increase the
volume of mixture.

Two-thirds of the worlds surface is covered with water. It is, therefore, not
supersizing that there has been much activity with concrete in sea in recent decades.
Numerous idea and schemes have been promoted and many have been executed.

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Following the acceptance of concrete by the oil companies and the success of very large
structure in the North Sea the use of floating concrete structure, i.e. mainly temporarily
floating structure is continually growing.

The advantages of floating concrete structure lie in the economy of the materials
used (concrete is very well suited to a marine environment), in the fact that it is easy to
make concrete structure buoyant in the construction stage by using lightweight concrete.

1.2.1 Advantages:

i. Excellent Acoustic Performance:

It can be used as effective sound barrier and for acoustic solutions. Hence, highly
suitable for partition walls, floor screens / roofing and panel material in auditoriums.

ii. Earthquake Resistant:

Since concrete is lighter than the brick, hence the lightness of the material increases
resistance against earthquake.

iii. Insulation:

Superior thermal insulation properties compared to that of conventional brick and


concrete, so reduces the heating and cooling expenses. In buildings, light-weight
concrete will produce a higher fire rated structure.

iv. Workability:

Products made from lightweight concrete are lightweight, making them easy to place
using less skilled labour. The bricks can be sawed, drilled and shaped like wood using
standard hand tools, regular screws and nails. It is simpler than brick or concrete.

v. Lifespan:

Lightweight concrete is weatherproof so the lifespan of concrete or structure is more.

vi. Savings in Material:

Reduces dead weight of filler walls in framed structures by more than 50% as
compared to brickwork resulting in substantial savings. Due to the bigger and uniform
shape of blocks, there is a saving in bed mortar and plaster thickness. In most cases the
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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15

higher cost of the light-weight concrete is offset by a reduction of structural elements,


less reinforcing steel and reduced volume of concrete..

vii. Skim Coating:

Do not require plaster. Wallpapers and plasters can also be applied directly to the
surface

1.2.2 Application of Floating Concrete


The ranges of applications of floating concrete in various fields are as follow:

In high rise building as non- structural unit like walls

Oil exploration and drilling platform

Oil Production platforms

Floating Docks

Floating Gates for dry docks

Floating airports

Floating Power Stations

Floating Hotels And Shopping centers

Floating Industrial plants

Floating Bridges

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1.2.3 Objectives

i. To reduce Dead load of Structure.

ii. To reduce Dead load of Structure.

iii. To decrease the Cost of Labours.

iv. To reduce Wastage of Materials.

v. To reduce Overall Cost of Structure.

vi. To improve Thermal Insulation.

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CHAPTER - 2
LITERATURE REVIEW

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2 Literature Review

2.1 History

The use of lightweight concrete has been a feature in construction industry for
centuries, but like other material the expectations of the performance have raised and now
we are expecting a consistent, reliable material and predicable characteristics.

Generally, the properties of lightweight concrete can be indicated by doing


laboratory testing, but the overall performance of the material can only be demonstrated
adequately by its performance in the field by testing lightweight concrete structure under
service. Lightweight concrete has been successfully used for marine applications and in
shipbuilding. Lightweight concrete ships where produced in the USA during the 1914-
1918 war, and there success led to the production of the USS Selma (a war ship).

In 1984, Thomas A. Holm estimated that there were over 400 lightweight
concrete bridges throughout the world especially in USA and Canada. The research
carried out by the expanded clay and slate institute prove that most of the bridge appeared
to be in good condition.

2.2 Literature Review of Papers

1) Dhawal Desai, Development of Light Weight Concrete, Civil Engineering


Portal, 2014 pp 5-15 - The author has done experimental study on two types of
lightweight concrete.
I. Lightweight concrete by using lightweight aggregates.

He used aggregates having low specific gravity which is highly porous materials. In
this type of concrete, conventional aggregates are replaced by lightweight aggregates like
Pumice Stones, over burnt bricks, etc. In this he also studied different types of lightweight
aggregates as,

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Inorganic natural aggregate


Organic natural aggregate
Manufactured aggregates

II. Aerated autoclave concrete using aluminium powder.


2) Autoclaved Aerated Concrete (AAC) or Autoclaved Lightweight Concrete
(ALC) is a pre-cast construction material that is made from a variety of aggregate
parts no larger than sand. At roughly one-fifth of the weight of normal concrete, it is
an incredibly lightweight building material. It provides excellent thermal and acoustic
resistance and also protects against household hazards as termites and fire. AAC is
commonly referred to as autoclaved cellular concrete because hydrogen bubbles form
during the production process, resulting in small pockets of air within the concrete that
substantially increase the volume of the final concrete product. Though the precise
composition of autoclaved aerated concrete may vary, it is generally made up of
quartz sand or some other fine aggregate, cement and water or some other binding
component and aluminum powder. The aluminum powder reacts with the cement and
forms hydrogen bubbles to form within the mix, thereby increasing the volume-to-
weight ratio of the concrete mix. After the mix is cast into the desired form and the
volume-increasing chemical reactions occur, the concrete mix which steel soft is
autoclaved. (Ref.1)

3) T. Parhizkar, M. Najimi and A.R. Pourkhorshidi , VOL. 13, NO. 1 (2012) pp. 43-
54. - have presented experimental investigation on the properties of volcanic pumice
lightweight aggregates concretes. To this end, two groups of lightweight concretes
(lightweight course with natural fine aggregate concrete, and lightweight coarse and
fine aggregate concrete) are built and the physical/ mechanical and durability aspects
of them are studied, the results of compressive strength, tensile strength and drying
shrinkage shows that this lightweight concrete meet the requirements of the structural
lightweight concrete.(Ref.2)

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4) N. Sivalinga Rao, Y. Radha Ratna Kumari, V. Bhaskar Desai, B.L.P. Swami,


Volume 4, Issue 5, May-2013 ISSN 2229-5518. - have studied on Fiber Reinforced
Lightweight Aggregate (Natural Pumice Stone) Concrete. In their studies the mix
design was M20 and the test results are as follows: More than the target mean strength
of M20 concrete is achieved with 20% replacement of natural coarse aggregate with
pumice aggregate and with 1.5% of fiber also with 40% pumice and with 0.5% of
fibers average target mean strength of M20 concrete is achieved.( Ref.3)

5) Lakshmi Kumar Minapu, M K M V Ratnam, Dr. U Rangaraju (2014),


International Journal of Innovative Research in Science, Engineering and Technology
Vol. 3, Issue 12, - studied about the lightweight aggregate with pumice stone, Silica
fume and Fly Ash as partial replacement of Coarse Aggregate. In design of concrete
structure, lightweight concrete plays a prominent role in reducing the density and to
increase the thermal insulation. This may related of both structural integrity and
serviceability. More environmental and economic benefits can be achieved if waste
material can be used to replace the fine light weight aggregate. The new source of
structural aggregate which is produced from environmental waste is natural
aggregates, synthetic light weight aggregate the use of structural grade light weight
concrete reduce the self-weight and helps to construct larger precast unit. In this study,
an attempt has been made to study the mechanical properties of structural grade light
weight concrete M30 using light weight aggregate pumice stone as a partial
replacement to coarse aggregate and mineral admixture material like Fly Ash and
Silica Fume. ( Ref.4)

6) Kl1, C. D. Atis, A. Teymen, O. Karahan and Kamuran Ar (2009), Scientific


Research and Essay Vol.4 (10), pp. 961-965, - this study examines the influence of
aggregate types on the unit weight and strength characteristics of lightweight concretes
(LWC). In this study, a scoria aggregate light weight concrete (SLWC), a pumice
aggregate light weight concrete (PLWC) and three scoria-pumice commixture
aggregate light weight concretes (SPLWC-I, SPLWC-II and SPLWC-III) were
produced. Average dry unit weights of SLWC, SPLWC-I, SPLWC-II, SPLWC-III and

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PLWC mixtures were 1997, 1696, 1638, 1477, 1368, kg/m3, respectively.
Compressive and flexural tensile strength and unit weight of concrete were determined
at 28 days. SLWC, SPLWC-I, SPLWC-II, SPLWC-III and PLWC mixtures developed
44.1, 30.5, 27.6, 23.3, 15.8 MPa compressive strength, respectively, which satisfy the
load bearing requirements. In terms of Strength and unit weight requirements, all
concrete produced can be classified as well as used as a LWC. ( Ref .5)

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CHAPTER - 3
METHODOLOGY

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3. Methodology

3.1 Material used in Project work


Cement Ordinary Portland cement.

Aggregate Pumice Stones 10 to 20mm

Sand Crushed sand passing through IS sieve size 4.75mm

Admixtures Aluminum Powder

Water Tap water

Water/Cement ratio - 0.5

Mixed Procedure Mixer mixing

Compaction Table Vibration

Curing practice - Moist curing by pounding

Cube size 15cm15cm15cm

Testing of cubes Compressive test after 7 & 28 days

Testing Machine Compressive Testing Machine (CTM)

3.2 Material Properties:

3.2.1 Cement:

The cement used was Ordinary Portland Cement of 53 grade confirming


to IS 12269. The cement should be fresh and of uniform consistency. Where
there is evidence of lumps or any foreign matter in the material, it should not be
used. The cement should be stored under dry conditions and for as short duration
as possible.

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3.2.2 Pumice Stones

Pumice stone is a lightweight aggregate of low specific gravity. It is a highly


porous material with a high water absorption percentage. In this we do not use the
conventional aggregate and replace it by the pumice stone.

Fig. 3.1 Pumice Stone

Pumice is created when super-heated, highly pressurized rock is violently ejected from
a volcano. The unusual foamy configuration of pumice happens because of simultaneous
rapid cooling and rapid depressurization. The depressurization creates bubbles by lowering
the solubility of gases that are dissolved in the lava, causing the gases to rapidly exsolve (like
the bubbles of CO2 that appears when a carbonated drink is opened). The simultaneous
cooling and depressurization freezes the bubbles in the matrix.

3.2.3 Water:

Water used in the mixing is to be fresh and free from any organic and harmful
solutions which will lead to deterioration in the properties of the mortar. Salt water is not to
be used. Potable water is feet for use mixing water as well as for curing.
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3.2.4 Admixtures:

Special consideration shall be given to the addition of the materials to the mortar for
special purposes. Approval may be given by the consulting engineer, when the materials are
to be added directly or indirectly to reduce the water to the cement ratio or according to
approval standards, if any. In this work, the admixtures used are namely Aluminium powder
and Fly Ash.

a) Aluminium Powder

Water floating aerated concrete is made by introducing air or gas into slurry
composed of Portland cement and sand, so that when the mix sets and hardens, uniform
cellular structure is formed. Thus it is a mixture of water, cement and finely crushed sand.
We mix fine powder of Aluminum to the slurry and it reacts with the calcium hydroxide
present in it thus producing hydrogen gas. This hydrogen gas when contained in the slurry
mix gives the cellular structure and thus makes the concrete lighter than the conventional
concrete.

Fig 3.2 Aluminium Powder

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b) Fly Ash:

Fly Ash is finely divided residue resulting from the combustion of powdered
coal and transported by the flue gasses and collected by electrostatic precipitator. Fly
Ash is the most commonly and widely used pozzolanic material all over the world. Fly
Ash was first use in large scale in the construction of Hungry Hose dam in America in
the approximate amount of 30% by weight of cement. In India it was used in Rihand
dam construction replacing cement up to 15%.

3.3 Moulds and Equipment:

Moulds of required size and shape were prepared for casting process the dimensions of
the moulds for the casting cubes are 150mm 150mm 150mm are used. All the moulds are
applied lubricant before concreting. After a day of casting, the moulds are demoulded and
then cubes are moved to the curing tank for the curing.

3.4 Testing of Materials

3.4.1 Cement

1) Standard Consistency Test

For finding out initial setting time, final setting time and soundness of cement and
strength parameter known as standard consistency has been used. The standard consistency of
cement paste is defined as that consistency which will permit a vicate plunger having 10 mm
diameter and 50 mm length to penetrate to a depth of 33-35 mm from the top of mould. Vicat
apparatus is used to find out the percentage of water required to produce a cement paste of
standard consistency.

Result of Standard Consistency Test is the percentage by weight with respect to


cement to produce standard consistency is 32%

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2) Fineness Test

The fineness of cement has an important bearing in the rate of hydration and hence on
the rate of gain of strength and also on the rate of evolution of heat. Finer cement offers a
greater surface area for hydration and hence faster the development of strength.

Data:-

Weight of cement taken (A) =100 gm.

Weight of cement retained on 90 I.S. Sieve (B) = 05 gm.

Calculation:-

Fineness = (B/A) 100

= 05%

I.S. requirement for fineness = less than 10%

Fineness = 05%

Fineness value is less than 10%. Hence it can be used in our project work.

3) Setting Time

Weight of cement = 300 gm.

Water content = 0.85 P .. Where P = Standard Consistency

= 0.85 34%

= 28.9% of cement

= (28.9100) 300 gm.

= 86.7 gm.

= 86.7 ml

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i. Initial Setting time:-

The periods elapsing between the time when water is added to the cement and the
time at which the needle penetrates the test block to the depth equal to 33-35 mm from the top
is taken as initial setting time.

I.S. requirement = more than 30 minutes (as per I.S. 4031-1968)

Initial setting time = 40 minutes

ii. Final Setting time:-

When the test block has attend such hardness that the needle does not pierce through
the block more than 0.5 mm, that time is known as final setting time.

I.S. requirement = less than 600 minutes (as per I.S. 4031-1968)

Initial setting time = 262 minutes

3.4.2Pumice Stone

Water Absorption:-

Data:-

Weight of pan (W1) = 540 gm.

Original weight of pumice stones (W2) = 880 gm.

Weight of pan + Dry weight Pumice Stone (W3) = 850 gm.

Weight of pan + Wet weight Pumice Stone (W4) = 930 gm.

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Fig. 3.3 - Pumice immersed in water

Calculations:-

Water Content = ((W4-W3) (W2-W1)) 100

= ((950-850) (880-540)) 100

= 29.41 %

Result: - Water Absorption of pumice Stones = 29.41 %

3.4.3 Aluminium Powder:-

The test is carried out for checking of how many percentage of volume of
concrete is increased by using aluminum powder. We have casted one specimen of size
15 cm15cm13.2 cm. It has been observed that after 24 hours height of specimen
increased by 2.5 cm.

Therefore increased in volume = (15 1515.7) (15 1513.2)

= 562.50 cm3

% Volume increased = (562.50 2970) 100

= 18.94 %

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Fig 3.4 Initial stage (just after casting)

Fig 3.5 Final stage (after one hour)

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Result:-

The percentage of volume of concrete is increased 18.94%

3.5 Experimental Program

In this experimental investigation, compressive strength of M-10 cement concrete


for various proportions of pumice stone (as aggregate) will be experimentally found out.
The Aluminum powder will be added in fix proportions (i.e. 2%) by weight of the
cement. The experimental results of various tests on lightweight concrete will be then
comparing with standard earth brick. We also try to find the right proportion of the
different size of the lightweight aggregate in concrete that make the strength of the
concrete maximum and make concrete floatable.

3.5.1 Casting of Specimens:-

For this project, we got pumice stone as big as 50 mm size. So we crushed it to the size
of 20 mm & less by using the sieve analysis. The mix design for the first sample is decided
based on the studies, and then further samples were made by changing some proportions in
previous ones.

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Fig3.6 - Size Reduction of Aggregate.

Fig.3.7 - Sieve analysis.

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3.5.2 Procedure:

1) Batching:

The measurement of materials for making concrete is known as batching.

2) Weigh Batching:

Weigh is the correct method of measuring the material. Use of weight system is
batching, facilitates accuracy, flexibility and simplicity.

Fig. 3.8 - Weigh Batching

3) Measurement of water:
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When weigh batching is adopted, the measurement of water must be done accurately.
Addition of water by graduated bucket in terms of liters will not be accurate enough for the
reason of spillage of water etc.

4) Preparation of concrete cubes:

Metal mould , preferably steel or cast iron, strong enough to prevent distortion is
required. They are made in such a manner as to facilitate the removal of moulds. Specimen
without damage and are so maintained that, when it is assembled, the dimensions and internal
faces are required to accurate within the following limits.

Fig.3.9 - Batching and Preparation of cubes.

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5) Compacting:

The testing cube specimens are made as soon as possible after mixing and in such a
manner to produce full compaction of the concrete with neither segregation nor excessive
bleeding.

Fig.3.10 - Tamping of Concrete

6) Curing:

The test specimens are stored in a place free from vibration in moist air of at
least 90% relative humidity and at a temperature of 27020C for 24 hours from the time
of addition of water to the dry ingredients. After this period the specimens are marked
and removed from the moulds.

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7) Testing:

Compressive strength:

After 28 days curing, cubical specimens are placed on compression testing


machine having a maximum capacity of 3000 KN and a constant rate of loading of 40
kg/m2/minute is applied on test specimen. Ultimate load at which the cubical specimen
fails is noted down from dial gauge reading. The ultimate load divided by the area of
specimen gives the compressive strength of each cube.

Fig.3.11 - Compression Testing Machine

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Fig. 3.12 Cube at a failure stage.

3.5.3 Preparation of Samples:

1) Sample1: 6 cubes

Cement: 19.15 kg

Crushed sand: 24.32 kg

Pumice stone (< 20 mm): 9 kg

Water: 10.53 kg

Admixture: Aluminium powder 2%

2) Sample2: 6 cubes

Cement: 9 kg

Pumice powder: 1.8 kg

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Crushed sand: 3 kg

Pumice stone: M1 (10 to 20 mm): 9.6 kg

M2 (4.75 to 10 mm): 2.4 kg

Water: 5.4 kg

Admixture: Aluminium powder 2%

3) Sample3: 6 cubes

Cement: 7.5 kg

Pumice powder: 3.5 kg

Crushed sand: 3 kg

Pumice stone: M1 (10 to 20 mm): 7.5 kg

M2 (4.75 to 10 mm): 3 kg

Water: 6.2 kg

Admixture: Aluminium powder 2%

4) Sample4: 6 cubes

Cement: 6 kg

Pumice powder: 3 kg

Pumice stone: M1 (10 to 20 mm): 6 kg

M2 (4.75 to 10 mm): 4 kg

Water: 5.8 kg

Admixture: Aluminium powder 2%

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5) Sample5: 6 cubes

Cement: 4.2 kg

Pumice powder: 3 kg

Pumice stone: M1 (10 to 20 mm): 4.6 kg

M2 (4.75 to 10 mm): 3.4 kg

Water: 3.6 kg

Admixture: Aluminium powder 2%

6) Sample6: 6 cubes

Cement: 6 kg

Pumice powder: 1.5 kg

Fly ash: 3 kg

Pumice stone: (< 10 mm): 10 kg

Water: 4.5 kg

Admixture: Aluminium powder 2%

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CHAPTER 4
RESULTS & DISCUSSION

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4. Results & Discussion

4.1Sample1:
4.1.1 Result:

Table No.4.1

Specimen Weight Density Average Load Strength Average


2
No. (kg) (kg/m3) Density (KN) (N/mm ) Strength
7 Days
1. 5.80 1719 272 12.09
2 5.76 1707 1707 247 10.98 11.68
3 5.72 1695 269 11.96
28 Days
4 5.86 1736 287 12.76
5 5.80 1719 1725 267 11.86 11.85
6 5.80 1719 246 10.93

Testing Results of sample 1

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Broken pumice
Aggregate

Fig. 4.1 Cube showing Broken aggregate & Voids

4.1.2 Observations & Discussion:


This sample gives average compressive strength 11.85 N/mm2, which is good for
lightweight concrete. Also it gives average density 1725 kg/m3, but we have to reduce the
density of concrete to nearly equals to density of water, so it is to be required that reduce the
quantity of crush sand and thats why we reduced the quantity of crushed sand and also
replaced it with pumice sand passing through IS sieve of size 4.75 mm. in next sample. Also
we used two fractions of Aggregate i.e. M1 (10mm to 20 mm) and M2 (4.75 mm to 10 mm).

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4.2 Sample2:
4.2.1 Results:

Table No.4.2

Specimen Weight Density Average Load Strength Average


2
No. (kg) (kg/m3) Density (kN) (N/mm ) Strength
7 Days
1. 4.84 1434 210 9.33
2 4.80 1422 1426 208 9.20 9.11
3 4.80 1422 199 8.80
28 Days
4 4.86 1440 262 11.64
5 4.90 1452 1440 284 12.62 11.46
6 4.82 1428 228 10.13

Testing results of Sample 2

4.2.2 Observations & Discussion:

This sample gives the improved results having average density 1440 kg/m3 and
average compressive strength 11.46 N/mm2, but average density of concrete is not nearly
equals to the density of water. Also the quantity of cement is high, so we discussed this
situation with our project guide. He told us that if reduce the quantity of cement it will help us
to reduce the density as well as to achieve economy. Therefore in next sample we reduced the
cement quantity and increased the pumice sand.

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4.3 Sample3:
4.3.1 Results:

Table No.4.3

Specimen Weight Density Average Load Strength Average


2
No. (kg) (kg/m3) Density (KN) (N/mm ) Strength
7 Days
1. 4.12 1221 105 4.67
2 4.10 1215 1216 102 5.53 4.90
3 4.09 1212 101 4.49
28 Days
4 4.14 1227 167 7.42
5 4.26 1262 1233 197 8.76 8.15
6 4.08 1209 186 8.27

Testing results of Sample 3

4.3.2 Observations & Discussion:


This sample gives the improved results having average density 1233 kg/m3 and
average compressive strength 8.15 N/mm2. We reduced the quantity of cement in this sample,
but average density of concrete is still not nearly equals to the density of water. Therefore in
next sample we again reduced the cement quantity and increased the pumice sand.

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4.4 Sample4:
4.4.1 Results:

Table No.4.4

Specimen Weight Density Average Load Strength Average


2
No. (kg) (kg/m3) Density (KN) (N/mm ) Strength
7 Days
1. 3.38 1001 75 3.33
2 3.58 1060 1045 105 4.67 3.92
3 3.62 1073 85 3.77
28 Days
4 3.82 1132 111 4.93
5 3.94 1167 1142 155 6.89 5.53
6 3.80 1126 107 4.76

Testing results of Sample 4

Fig 4.2- Cube Showing Rough surface.

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4.4.2 Observations & Discussion:

Sample 4 gives lightweight concrete having average compressive strength 5.53


N/mm2and average density 1045 kg/m3, which is nearly equal to the density of water hence
the concrete may be float on the water. It was light as desired but its finishing was not good. It
happens because of the large sized aggregate. So we have decided to eliminate large size
aggregate completely from concrete & also replace 30% cement by fly ash to achieve
economy.

4.5 Sample5:
4.5.1 Results:

Table No.4.5

Specimen Weight Density Average Load Strength Average


2
No. (kg) (kg/m3) Density (KN) (N/mm ) Strength
7 Days
1. 3.21 951 56 2.48
2 3.24 960 968 62 2.76 2.56
3 3.35 992 55 2.44
28 Days
4 3.02 895 65 2.89
5 2.98 883 903 68 3.02 3.21
6 3.14 930 84 3.73

Testing results of Sample 5

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(a)

(b)

Fig. 4.3 Cube floating on water

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4.4.2 Observations & Discussion:

Sample 5 gives lightweight concrete having average compressive strength 3.21


N/mm2and average density 903 kg/m3. Which is less than the density of water hence the
concrete cube floating on the water? Figure 4.3 shows the cube floating on water. It was light
as desired but its finishing was not good. It happens because of the large sized aggregate. So
we have decided to eliminate large size aggregate completely from concrete & also replace
30% cement by fly ash to achieve economy.

4.6 Sample 6:
4.6.1 Results:

Table No.4.6

Specimen Weight Density Average Load Strength Average


2
No. (kg) (kg/m3) Density (KN) (N/mm ) Strength
7 Days
1. 4.04 1197 91 4.04
2 4.04 1197 1189 112 4.98 4.52
3 3.96 1173 102 4.53
28 Days
4 3.84 1137 202 8.97
5 3.65 1081 1102 196 8.71 8.62
6 3.68 1090 184 8.17

Testing results of Sample 6

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Fig. 4.4 - Cube Showing Smooth Surface

4.6.2 Observations & Discussion:

Sample 6 gives lightweight concrete having surface flat & smooth and
showing a good finish. Its average density 1102 kg/m3 and average compressive
2
strength 8.62 N/mm . From the above results it seems that the compressive strength
is increased even if the density is nearly same as the previous sample. So this sample
is perfect for the mix proportion.

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4.6 Graphical Representation of Compressive Strength and


Density:

Compressive strength
Compressive strength
14

12

compressive 10
strength
(N/mm2) 8

0
sample 1 sample 2 sample 3 sample 4 sample 5 sample 6

Chart4.1: Compressive Strength of Different Samples

Density
Density

2000
1800
1600
1400
1200
1000
Density 800
(kg/m3)
600
400
200
0
sample 1 sample 2 sample 3 sample 4 sample 5 sample 6

Chart4. 2: Density of Different Samples

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4.7 Selection of Mix Proportion:

From the above results & discussions we selected the sample 6 as final mix proportion
of our project, because it gives better compressive strength and low density with smooth
surface.

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CHAPTER 5
COMPARISON & CONCLUSION

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5. Comparison & Conclusion

5.1 Comparison between Brickwork and Floating Concrete:

5.1.1 Comparison based on Density:

Our first objective of this project is to reduce the dead load of the structure. For that we
have to reduce the density of our concrete and this density should be less than the density of
earth brick, i.e. 1800 kg/m3. The density of our concrete is 1250 kg/m3, which is less than the
density of the earth bricks. So we achieved our objective.

5.1.2 Comparison based on strength:

If we compare the compressive strength of our concrete with earth bricks, it gives
satisfactory results, because the compressive strength of brick is 3.5 N/mm2 and that of our
concrete is 4.52 N/mm2, which is greater than the compressive strength of brick.

5.1.3 Comparison based on cost:

For the comparison of cost of brickwork and the cost of floating concrete we did
the cost analysis of both works. Cost analysis is done as shown below:

I. Cost analysis of brickwork:

Consider 10 m3. Brickwork.

Bricks:

Brick size with mortar layer is 20cm10cm10cm. Therefore volume of one brick

= 0.20.10.1

= 0.002 cu m.

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Therefore number of bricks required = volume of wall volume of one brick

= 10 0.002 = 5000 Nos.

Consider 5% breakages, wastages, etc.

Therefore total bricks required = 5000 + 5000 (5 100)

= 5250 Nos.

Mortar:

Actual size of brick is 19cm9cm9cm and volume is 0.001539 cu m.

Therefore volume of mortar = total volume of brickwork net volume of brickwork

= (0.002 0.001539) 5000

= 2.305 cu m.

For frog filling, for use of cut bricks, for bonding, for uniform joints, wastages, etc. 20% extra
mortar may be required.

Therefore volume of mortar = 2.305 + 2.305 (20 100)

= 2.766 cu m.

For wet volume increase dry volume 1/3 dry volume of mortar,

Therefore wet volume of mortar = 2.766 + (1 3) 2.766

= 3.688 cu m.

Calculation of materials of mortar;

Mix proportion of cement and sand is 1:3.

Therefore cement required = 3.688 4

=0.922 cu m

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Number of cement bags required = 0.922 0.035

= 26.34 bags, say 27 bags

Sand required = 0.922 3

= 2.766 cu m.

Table No 5.1

Materials Quantity or Nos. Rate Cost


Bricks 5250 nos. 7Rs. per brick 36750.00
Cement 27 bags 380Rs. per bag 10260.00
Sand 2.766 cu m. 3500Rs. per cu m. 9695.00
Total = 56705.00
Add 1% for water charges = 567.05

Add 5% for suppliers profit = 2835.25


Grand total = 60107.3

Cost Analysis of Brick Work

Therefore cost of materials for 1 cu m = 60107.3 10 = 6010.73Rs, say 6011 Rs.

II. Cost analysis of our concrete work:

Consider 1 cu m concrete work.

As per the sample 6 the quantities required for 6 cubes are shown below:

Table No 5.2

Cement (kg) Pumice powder (kg) Fly Ash (kg) Pumice stone (kg)
6 1.5 3 10

Materials Required For 6 Cubes

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Volume of 6 cubes = 6 (0.153)

= 0.02025 m3.

Calculation of materials required for 1 cu m concrete.

Cement = (6 0.02025) 1

= 296.30 kg.

= (296.30 50)

= 5.92 bags, say 6 bags.

Fly Ash = (3 0.02025) 1

= 148.15 kg.

Pumice Powder = (1.5 0.02025) 1

= 74.07 kg.

Pumice Stone = (10 0.02025) 1

= 493.82 kg.

Total pumice required = 74.07 + 493.82

= 567.89 kg

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Table No 5.3

Materials Quantity or Nos. Rate Cost


Cement 6 bags 380 2280.00
Fly Ash 148.15 kg 2 Rs. per kg 296.30
Pumice Stone 493.82 kg 5 Rs. Per kg 2469.10
Total = 5045.4
Add 1% for water charges = 504.54
Add 5% for suppliers profit = 252.27
Grand total = 5802.21

Cost Analysis of Floating Concrete

Total cost of materials = 5810 Rs.

III. Statement

From the above two cost analysis the cost of materials for both works is same, but due
to the lightweight handling of materials is easy, so number of labours require are less than that
of the brickwork. Therefore labour cost is minimum for Floating Concrete

5.1.4 Savings of Materials:

This concrete reduces dead weight of filler walls in framed structures by more than
50% as compared to brickwork resulting in substantial savings. Due to the direct casting of
concrete in moulds of wall, there is a saving in bed mortar and plaster thickness. In most cases
the higher cost of the light-weight concrete is offset by a reduction of structural elements, less
reinforcing steel and reduced volume of concrete.

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5.3 Conclusion:

In this study, the influences of aggregate types and the amount on the compressive
strength of concrete were investigated. Using different aggregate proportions (pumice) and
five different lightweight concrete mixtures were produced with a satisfied strength. The
result of the investigation showed that aggregate size and proportion influenced the unit
weight and compressive strength of concrete. Moreover, the result showed that it is possible
to produce a Floating and satisfied strength concrete by using pumice as aggregate. It was also
seen that, using light weight aggregate in the concrete mixture can reduce the dead load but
decreases the concrete strength. However for the sample 6 it is Reverse, because this
proportion gives compressive strength 8.62 N/mm2, which is good for the light weight
concrete having density 1102 kg/m3. From cost analysis it is proved that the cost of our
project is less than that of brick masonry.
The study showed that using pumice aggregate as a commixture enable to produce
different strength grade lightweight concrete with different unit weight. These concrete does
not satisfies the strength requirements for load bearing structural elements.
In this study only strength and unit weight were considered, other properties including
carbonation and drying shrinkage, thermal conductivity and sound insulation properties can
be investigated as a further study.

5.2 Future Trend of Project

Now days many high rise buildings are constructed all over the world, for that it is
required that the dead load of the buildings should be less. So light weight concrete
has great demand in the construction field.
In the world construction work becomes so faster. So it is necessary that the speed of
construction should be increased. To achieve the speedy construction light weight
concrete is used.
This concrete provides good quality building material that can be satisfy the condition
of hot coastal environment.

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CHAPTER - 6
REFERENCES

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6. References

1) Dhawal Desai, Development of Light Weight Concrete, Civil Engineering Portal,


2014.
2) T. Parhizkar*, M. Najimi and A.R. Pourkhorshidi, (Application of pumice aggregate in
structural lightweight concrete, Asian journal of civil engineering (building and
housing) VOL. 13, NO. 1 (2012) PAGES 43-54.
3) N. Sivalinga Rao, Y.Radha Ratna Kumari, V. Bhaskar Desai, B.L.P. Swami, Fibre
Reinforced Light Weight Aggregate (Natural PumiceStone) Concrete, International
Journal of Scientific & Engineering Research Volume 4, Issue 5, May-2013 ISSN 2229-
5518.
4) Lakshmi Kumar Minapu1, M K M V Ratnam2, Dr. U Rangaraju, (Experimental Study
on Light Weight AggregateConcrete with Pumice Stone, Silica Fume and Fly Ash as a
Partial Replacement of Coarse Aggregate), International Journal of Innovative Research
in Science, Engineering and Technology Vol. 3, Issue 12

5) Kl1, C. D. Atis, A. Teymen, O. Karahan and Kamuran Ar (2009), (The effects of


scoria and pumice aggregates on the strengths and unit weights of lightweight concrete ),
Scientific Research and Essay Vol.4 (10), pp. 961-965

6) Banthia, N. and Trottier, J., Concrete reinforced deformed steel fibbers, part 1: Bond-
slip mechanisms, ACI MaterialJournal 91 (5) (1994) 435-446.

7) Compione, G.,Mindess, S. and Zingone, G., compressive stress-strain behavior of


normal and high- strength Carbone- fiber concrete reinforced with steel spirals. ACI
MaterialsJournal 96 (1) (1999) 27-34.

8) Balaguru, P. and Ramakrishnan, V. Properties of lightweight fibre reinforced


concrete, Fibre Reinforced concrete-Properties and applications, SP105, American
Concrete Institute, Detroit, Michigan, 1987.pp. 305-322.

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Floating Concrete By Using Light Weight Aggregate & Air Entraining Agent, 2014-15

9) Al-Jabri KS, Hago AW, Al -Nuaimi AS, Al -Saidy AH (2008). Concrete blocks for
thermal insulation in hot climate. Cem. Concr. Res. 35: 1472-1479.

10) Al-Khaiat H, Haque MN (1998). Effect of initial curing on early strength and physical
properties of lightweight concrete. Cem. Concr. Res. 28: 859-866.Kilic et al. 965

11) Bamforth PB (1980). In situ measurement of the effect of partial Portland cement
replacement using either fly ash or ground granulated blast furnace slag on the
performance of mass concrete. Proc. Inst. Civ. Eng. 69: 777-800.

12) Kili A, Ati_ CD, Ya_ar E, zcan F (2003). High strength lightweight concrete made
with scoria aggregate containing mineral admixtures. Cem. Concr. Res. 33: 1595-1599.

13) Yasar E, Atis CD, Kilic A, Gulsen H (2003). Strength properties of lightweight concrete
made with basaltic pumice and fly ash. Mater. Lett. 57: 2267-2270.

14) Failla A, Mancuso P, Miraglia N, Ruisi V (1997). Experimental theoretical study on


pumice aggregate lightweight concrete. Technical Report, The Instuto di Scienza delle
Costrurioni, Facolta di Ingegneria, Palermo; Published by Ministero delta Publica
Instuzione, Palermo, Italy pp. 3-22.

15) Gunduz L (2008). The effects of pumice aggregate/cement ratios on the low-strength
concrete properties. Constr. Build. Mater. 22: 721-728.IMO (1997). Code of Earthquake
for Buildings. Turkish Chamber of Civil Engineering Turkish, Ankara, Turkey.

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7. Achievement

1. Participated and won first prize in National level Technical fest SHODH 2K15
Project Presentation.

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Team Presenting Papers on Project

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Project Team

Project Members with Project Guide

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