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CHAPTER 4

MATERIALS AND METHODS

4.1 MATERIAL DESCRIPTION

4.1.1 Cement

Cement is one of the major ingredient in concrete. It is a binder

material which is capable of bonding material fragments in to solid mass.
The Ordinary Portland cement was classified into three grades namely
33 grade, 43 grade and 53 grade. This classification of 33, 43 and 53 grade
is based on the strength of cement at 28 days, when tested as per IS 4031-
1988. If the 28 days strength is not less than 33 N/mm2, it is called 33 grade
cement, if the strength is 43 N/mm2, it is called 43 grade and if the strength
is not less than 53 N/mm2, it is called 53 grade. Ordinary Portland cement
of 43 grade was used for this experimental work. The properties of cement
listed in Table 4.1 was adopted from IS 4031.

Table 4.1 Chemical properties of cement

Sl.No Components Weight

1 Lime (CaO) 63%
2 Silica (SiO2) 21.9%
3 Alumina (Al2O3) 6.9%
4 Iron oxide (Fe2O3) 3%
5 Magnesium oxide (MgO) 2.5%
6 Sulphur trioxide & loss of ignition (SO3) 1.7%
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Table 4.2 Physical properties of cement

Sl.No Components Weight

1 Specific gravity 63%
2 Fineness 21.9%
3 Initial setting time 6.9%
4 Final setting time 3%
5 Standard consistency 2.5%
6 Compressive strength 1.7%

Same grade of cement is used for all the specimen. Usage of higher
grade cement increase the material cost but in turn offers 10-20% saving in
cement consumption, compared to lower grades.

4.1.2 Tyre Rubber

Rubber tyres may be classified into two major groups as tyres

from light vehicle and heavy vehicle. This project is based on the usage of
waste rubber tyres from light vehicles such as bikes and cars. Waste tyres
were collected from the available local resources. The tyres were manually
chopped into small pieces of required shape and size as shown in Figure
4.2. The maximum of the size of aggregate was 20 mm. chopped rubber
pieces were thoroughly cleansed with pure water and are sun dried. The
chopper rubber tyre pieces were shown in the Figure 4.1.
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Figure 4.1 Tyre rubber

Figure 4.2 Chopped rubber pieces

All the faces of the rubber tyre pieces were roughened manually.
Coarse aggregates were replaced with various percentage of discarded tyre
rubber. The specific gravity of rubber tyre waste was found to be 1.123.
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4.1.3 Aggregate

Aggregates are the primary constituents of concrete. In early

times aggregates were considered to be an inert material but recent
researches proved that they are reactive to some extent. As aggregates
occupies major volume of concrete, changes in their property impose a
major influence in the entire property of concrete. Good gradation of
aggregates are necessary for producing workable concrete.

Figure 4.3 Coarse aggregate

Figure 4.4 Fine aggregate

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Table 4.3 Properties of coarse aggregate

Sl. Obtained Limited

Test As per Codes Remarks
No Values Values
Specific IS 2386-1963
1 2.82 2.5-3 Satisfied
gravity (Part 3)
Fineness
2 7.03 6.5-8 IS 383-1970 Satisfied
modulus
Aggregate 45%(Not IS 2386-1963
3 15% Satisfied
impact value exceeds) (Part 4)

Aggregate IS 2386-1963
4 14.13% 45%(Not Satisfied
crushing value (Part 4)
exceeds)
Aggregate 30%(Not IS 2386 -1963
5 18% Satisfied
abrasion value exceeds) (Part 4

Table 4.4 Properties of fine aggregate

Sl. Obtained Limited As per

Test Remarks
No Values Values Codes
Specific
1 2.6 2.6-2.9 IS 383-1970 Satisfied
gravity
Fineness
2 2.47 2.2-3.3 IS 383-1970 Satisfied
modulus
1636.67
3 Bulk density 1520-1680 IS 383-1970 Satisfied
kg/m3

Well graded coarse aggregate of size 20mm were used in this

study. Fine aggregates are obtained from local resources confirming to zone
II of IS: 383 – 1970. The sand was sieved through 4.75mm sieve to remove
any particle greater than 4.75mm.
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4.1.4 Copper Slag

Copper slag is obtained during production of copper in copper

industries. The copper slag used for this experiment is shown in the Figure
4.4. The copper slag as shown in Figure 4.5 is obtained from the sterlite
industry in tuticorin, Tamilnadu, India. Sterlite Industry in tuticorin
produces 0.4 million tons of copper every year.

Figure 4.5 Copper slag

Table 4.5 Physical properties of copper slag

Sl.No Physical Properties Copper Slag

1 Particle Shape Irregular
2. Type Air Cooled
3. Appearance Black and glassy
4. Specific Gravity 3.91
5. Water Absorption % 0.15-0.20
6. Bulk Density 2.08
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Particle sizes are of the order of sand and its physical properties
are similar to natural sand. The properties of copper slag listed in Table 4.3
and 4.4.

Table 4.6 Chemical composition of copper slag

Sl. No. Chemical Properties Composition (%)

1. Loss on ignition(L.O.I.) 2.18
2. Silica(SiO2) 71.6
3. Magnesium oxide(MgO) 0.50
4. Calcium oxide(CaO) 0.17
5. Aluminum oxide(Al2O3)) 13.97
6. Iron oxide (Fe2O3) 3.65
7. Potassium oxide(K2O) 1.9
8. Sodium oxide(Na2O) 4.12
9. Titanium oxide(TiO2) 0.014
10. Copper oxide(CuO) 0.33
11. Manganese oxide (Mn2O2) 0.07

4.1.5 Water

Another important ingredient of concrete is water. Water

initiates the hydration reaction of cement in concrete which provides the
binding capacity for cement. Thus proper precautions must be taken
regarding the quantity of water used. Water also provides workability in
concrete. Quality of water should be maintained to attain desired strength.

In this study fresh portable water is used for mixing and curing
conforming to IS 456 – 2000.
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4.2 MIX PROPORTION DESIGNATIONS

Mix Design can be defined as the process of selecting

ingredients of concrete and determine their relative proportions with the
object of producing concrete of certain minimum strength and durability as
economically as possible. The object of any mix proportion method is to
determine an economical combination of concrete constituents that can be
used for a first trail batch to produce a concrete that is close to that which
can achieve a good balance between the various desired properties of
concrete at the lowest possible cost. The common method of expressing the
proportions of ingredients of a concrete mix is in the terms of parts or ratios
of cement, fine and coarse aggregates. The proportions are either by volume
or by mass. The water-cement ratio is usually expressed in mass.
Depending upon the level of quality control available at the site, the
concrete mix has to be designed for the target mean strength, which is
higher than the characteristic strength. The Mix proportion used for the
study was M30 (1:1.49:3.29: 0.50) grade concrete

Table 4.7 Mix proportion for M30 grade concrete

Cement Fine Aggregate Coarse Aggregate Water
Kg/m3 Kg/m3 Kg/m3 Kg/m3
383 572.125 1259.87 191.6
1 1.49 3.29 0.5

4.3 PREPARATION OF SPECIMENS

4.3.1 Batching of Concrete

Batching of concrete is the process of measuring concrete mix

ingredients either by volume or by mass and introducing them into the
mixture. Traditionally batching is done by volume but most specifications
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require that batching be done by mass rather than volume. Here, in this
project weigh-batching system was adopted. Percentage of accuracy,
flexibility and simplicity in usage is more in weigh batching system when
compared to volume batching system.
Table 4.8 Weight batching of concrete beam

Copper Rubber
Cement Copper Rubber
FA slag (% Tyre (%
Mix (Kg) slag CA Tyre
(Kg) replace replace
(Kg) (Kg) (Kg)
-ment) -ment)

M1 12.2 9.16 35 4.8 30.13 - -

M2 12.2 8.36 40 5.6 30.13 - -
M3 12.2 7.66 45 6.3 30.13 - -
M4 12.2 8.36 40 5.6 27.88 7.5 2.25
M5 12.2 8.36 40 5.6 27.13 10 3
M6 12.2 8.36 40 5.6 26.33 12.5 3.8

Table 4.9 Weight batching of concrete cube

Copper Rubber
Copper CA Rubber
Mix Cement FA slag (% Tyre (%
slag (Kg) Tyre
(Kg) (Kg) replace- replace-
(Kg) (Kg)
ment) ment)

M1 1.75 1.30 35 0.69 4.32 - -

M2 1.75 1.21 40 0.79 4.32 - -
M3 1.75 1.10 45 0.89 4.32 - -

M4 1.75 1.21 40 0.79 4.0 7.5 0.32

M5 1.75 1.21 40 0.79 3.89 10 0.43
M6 1.75 1.21 40 0.79 3.78 12.5 0.54
Table 4.10 Weight Batching Of Concrete Cylinder
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Copper Rubber
Copper CA Rubber
Mix Cement FA slag (% Tyre (%
slag (Kg) Tyre
(Kg) (Kg) replace replace-
(Kg) (Kg)
-ment) ment)
M1 2.75 2.2 35 0.93 6.79 - -

M2 2.75 1.88 40 1.25 6.79 - -

M3 2.75 1.72 45 1.41 6.79 - -

M4 2.75 1.88 40 1.25 6.29 7.5 0.50

M5 2.75 1.88 40 1.25 6.11 10 0.68

M6 2.75 1.88 40 1.25 5.94 12.5 0.85

4.3.2 Preparation of moulds

Before mixing of concrete the moulds in which the specimen are

to be casted was prepared. The interior surfaces of the mould was properly
cleaned and coated with mould oil for the purpose of lubrication. The sides
of the moulds are properly clamped with nuts and bolts so that the inner
faces make 90⁰ with each other as well as with the base plate and to avoid
leakage of water from the freshly mixed concrete.

Table 4.11 Sizes of moulds

Specimen Size Of Mould Adopted (in mm)

Cube 150 x 150 x 150

Cylinder 150 x 300

Beam 750 x 150 x 150

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4.3.3 Mixing of concrete

The mixing operation consists of rotation or stirring, the

objective being to coat the surface of all aggregate particles with cement
paste, and to bind all the ingredients of the concrete into a uniform mass,
this uniformity must not be disturbed by the process of discharging from the
mixer. The mixing should ensure that the mass become homogeneous,
uniform in colour and consistency. Here, in this project Hand mixing was
adopted.

4.3.4 Casting and compacting of concrete

The operation of casting and compacting of concrete are

interdependent and are carried out simultaneously. They are most important
for the purpose of ensuring the requirements of strength, impermeability
and durability of hardened concrete in the actual structure. As for as placing
is concerned, the main objective is to deposit the concrete as close as
possible to its final position so that segregation is avoided and the concrete
can be fully compacted. The concrete once mixed is filled within the mould
in three layers and each layers are tamped with the standard tamping rod.
The compaction using tamping rod should be properly done in order to
remove entrapped air and to avoid the formation of honey combing on the
sides.

4.3.5 Demoulding of specimens

Once the concrete specimen has been casted it is allowed to dry

for 24 hours so that, the concrete specimen attains required strength such
that it can be demoulded from the mould without causing damage to the
sides of the specimen. Care should be taken to ensure the proper removal of
mould as any damage can cause decrease in strength of specimen.
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4.3.6 Curing

Curing is the process in which the concrete is protected from loss

of moisture and kept within a reasonable temperature range. This process
results in concrete with increased strength and decreased permeability.
Curing is also a key player in mitigating cracks, which can severely affect
durability. Concrete that has been specified, batched, mixed, placed and
finished can still be a failure if improperly or inadequately cured. Here in
this project once the concrete specimen has demoulded it was kept in
ordinary curing tank and cured for 7, 14 and 28 days.

4.4 EXPERIMENTAL PROGRAM

4.4.1 Test on fresh concrete

4.4.1.1 Slump test

Slump test is used to determine the workability or to measure the

consistency of fresh concrete, where the nominal maximum size of
aggregates does not exceed 38mm using slump test apparatus. Slump test as
per IS: 1199-1959 is followed. The apparatus used for doing slump test are
slump cone and tamping rod. The slump test is an indirect measurement of
concrete consistency. The procedure for doing slump test is as follows:
The internal surface of the mould is thoroughly cleaned and
applied with a light coat of oil. The mould is placed on a smooth,
horizontal, rigid and nonabsorbent surface. The mould is then filled in four
layers with freshly mixed concrete, each approximately to one fourth of the
height of the mould. Each layer is tamped 25 times by the rounded end of
the tamping rod. After the top layer is rodded, the concrete is struck off the
level with a trowel. The mould is removed from the concrete immediately
by raising it slowly in the vertical direction. The difference in level between
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the height of the mould and that of the highest point of the subsided
concrete is measured. The difference in height in mm is the slump of the
concrete.

4.4.2 Tests on hardened concrete

4.4.2.1 Compressive strength tests

A compression test determines behavior of materials under

crushing loads. Once the curing period of particular specimen was gets over
they were taken out and allowed to dry for sometimes. Then the cube of
size 150mmx150mmx150mm was subjected to test as per IS: 516-1959. A
standard compressive testing machine of 1000KN capacity was used in this
project. The specimen was placed between the steel plates of compression
testing machine.

Once the specimen was placed the plunger was lowered such that
it touches the top of the cube gently without jamming the surface of the
cube. After the proper positioning of the specimen the load was gradually
applied on the surface of the cube till it reaches it ultimate load. As it
reaches the failure, the load in which the failure takes place was noted from
the dial gauge of the compressive testing machine. The compressive
strength of the cube specimen was calculated using the following formula:
Compressive Strength, fc = P/A N/mm2.
Where, P = Load at failure in N
A = Area subjected to compression in mm2.

4.4.2.2 Split tensile test

A direct measurement of ensuring tensile strength of concrete is

difficult. One of the indirect tension methods is split tension test. The split
tensile was carried out on cylinder of 150 mm diameter and 300mm height
using universal testing machine. The cylinder which was cured for required
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days was placed between steel plates longitudinally. Once the specimen was
properly placed between the plunger the load was applied gradually as per
IS 5816- 1999 till it reaches the load in which it fails. The split tensile
strength of the cylinder was calculated using the following formula:
2P
Split Tensile Strength =
LD
Where, P = Compressive Load in N
L = Length in mm
D = Diameter in mm

4.4.2.3 Flexural strength test

Flexural strength, also known as modulus of rupture, bend

strength, or fracture strength a mechanical parameter for brittle material, is
defined as a material's ability to resist deformation under load. The
transverse bending test is most frequently employed, in which a specimen
having either a circular or rectangular cross-section is bent until fracture or
yielding using a three point flexural test technique.
The flexural strength represents the highest stress experienced
within the material at terms of stress,here given the symbol calculated using
the following formula:

The flexural strength when a >13.3 cm for 10 cm specimen, f fb = Pa / bD2

The flexural strength when a < 13.3cm for 10 cm specimen, f fb = 3Pa / bD

Where, b = measured width of specimen in cm

d = measured depth in cm of the specimen at the point of failure.
a = distance of the crack from the nearer support in cm
P= maximum load in Kg applied to the specimen