“DESIGN AND EVALUATION OF

HIGH VOLUME FLYASH CONCRETE

FOR RIGID PAVEMENT OVER LAYS”
 SRI SIDDHARTHA INSTITUTE OF TECHNOLOGY
MARALUR, TUMKUR-572105.
DEPARTMENT OF CIVIL ENGINEERING

Under the Guidance of:

PROJECT ASSOCIATES
Mr. B. H. MANJUNATH
M.E (HIGHWAY ENGINEERING) NIKHIL.T.R
Lecturer, CHETHAN.J
DEPARTMENT OF CIVIL SUMATHI.H.D
ENGINEERING GURUNATH.N.R
SSIT, TUMKUR
 Compatibility study of different cements with the super
plasticizers using MARSH CONE.

 Workability measurement in respect of optimum dosage of

admixtures as determined by marsh cone.

 Proportioning and mix design as per code IS 10262-1982.

 Evaluations of properties of concrete in its green state.

 
 Evaluation for pavement overlay properties like compressive
strength, , flexural strength , modulus of elasticity etc as per
available standard methods
 The concrete construction industry is the one which can be
trusted to dispose of these materials, in particular road
sectors, where there is lot of room to consume this waste
material to a utility. High volume fly ash concrete is the one
which can be beneficially used for the construction of rigid
pavements

 Environmental pollution is avoided

 Usage of cement can be minimized to some extent that

may lead to sustainable development

 Long life and durable pavements

 Literature survey

 Collection of materials like aggregates ,cement ,superplasticizers,

Fly ash, etc..

 Fabrication of marsh cone equipment

 Various tests on the materials to be conducted

 Based on the test result of materials, mix design is done in

accordance to Draft code IS 10262-1982

 Using the mix design, cubes, cylinder and beams are caste and tested
for various properties

 Based on the results obtained conclusions are drawn

 CHEMICAL ADMIXTURES

 In Liquid form
• Additional material added  Modifies the workability
to concrete in order to properties
improve a particular 
 Best if
Best if added
added to
to the
the mixing
mixing
property of concrete to water
water
make it more suitable for  Plasticizers, Water
Water reducers,
reducers,
 Plasticizers,
any situation Super plasticizers,
plasticizers, Retarders,
Retarders,
Super
Accelerators, Air
Accelerators, Air entraining
entraining
Properties altered are agents.
agents.

 Rate of hydration MINERAL ADMIXTURES

 Setting time  In Finely divided form
 Workability  Modifies strength &
 Dispersion
workability properties
 Air entrainment
 Added to concrete or during
 Strength
production of cement itself
 Segregation & durability
 Fly ash, Silica fume, Rice
husk ash(RHA), Surkhi
Portland cement has a
tendency to flocculate in wet
concrete. The flocculation’s
entrap some amount of water
used in the mix and hence all
the water is not freely
available to the fluidity mix.
When Plasticizers are used
they get absorbed on cement
particles. The adsorption of
charged polymer on the
particles of cement creates
particle to particle
repulsion .The repulsion
releases the water held in
cement grains
 Methods available for
Tests made to know compatibility studies
fluidity of cements using Marsh cone test
some super plasticizers Mini slump test
Flow table test
 Some super plasticizers
may show higher
fluidizing effect on same
type of cement than
other cement.

 Optimum fluidizing
effect at lowest dosage is
an economical
consideration
LINE DIAGRAM OF MARSH CONE
Procedure

 Take 2kg cement, proposed to be

used at the project. Take one liter
of water (w/c=0.5) and say 0.1% of
plasticizer.
 Mix them thoroughly in a
mechanical mixer for two minutes
 Take one liter slurry and pour it in
to the marsh cone duly closing the
aperture with a finger.
 Start a stop watch and
simultaneously remove the finger.
Find out the time in seconds, for
complete flow out of the slurry,
and the time in seconds is called
the “Marsh cone time”.
 Repeat the test with different
dosages of plasticizer
  The dose at which the marsh cone
time is lowest is called the Saturation
point beyond which the flow time
does not decrease appreciably.

 The dose is the optimum dose for

that brand of cement and super
plasticizer for that w/c ratio.

 The test could be carried out for

various brands of cement and various
percentage of super plasticizer at
constant w/c ratio.

 Each test takes hardly 15 minutes

GRAPH OF MARSH CONE TIME V/S SUPER

PLASTICIZERS
 GRAPH OF MARSH CONE TIME V/S
SUPER PLASTICIZERS

Percentage of Marsh cone time

superplasticizers Graph of BRAND 1 cement

0.8 17.00

1.0 15.00

1.2 13.12

1.4 12.40

1.6 11.88

1.8 11.00

2.0 10.48

2.2 9.92
 GRAPH OF MARSH CONE TIME V/S
SUPER PLASTICIZERS

Percentage of Marsh cone time Graph of BRAND 2 cement

superplasticizers

0.8 16.00

1.0 14.08

1.2 12.88

1.4 13.92

1.6 13.00

1.8 14.00

2.0 13.16

2.2 12.60
 GRAPH OF MARSH CONE TIME V/S
SUPER PLASTICIZERS

Percentage of Marsh cone time

superplasticizers Graph of BRAND 3 cement

0.8 16.50

1.0 16.00

1.2 14.96

1.4 14.48

1.6 13.12

1.8 12.64

2.0 12.08

2.2 11.40
 GRAPH OF MARSH CONE TIME V/S
SUPER PLASTICIZERS

Percentage of Marsh cone time Graph of BRAND 4 cement

superplasticizers

0.8 24.00

1.0 20.00

1.2 18.08

1.4 17.60

1.6 16.00

1.8 15.00

2.0 14.20

2.2 13.20
SL. No. Test Results Requirements as per
IS:8112-1989
1. Normal Consistency 37% Not Specified

2. Initial Setting Time 45 min Shall not be less

than 30 minutes
3. Final Setting Time 325 min Shall not be more
than 600 minutes

4. Specific Gravity 2.97 Not Specified

5. Compressive 24.05 N/mm2 Shall not be less

Strength 43.85 N/mm2 than 23 N/mm2
a)3 days 44.27 N/mm2 Shall not be less
b)7 days than 33 N/mm2
c) 14 days

6. Fineness 3% Should be less than

10 % of its weight
Characteristic Strength of concrete = 60N/mm2
Maximum size = 20 mm
Compaction Factor = 0.80
Exposure = Moderate
Specific Gravity of cement = 2.97
Specific Gravity of Coarse Aggregates = 2.65
Specific Gravity of Fine Aggregates = 2.57
Water absorption of Coarse Aggregates = 0.45
Water absorption of Fine Aggregates = 0.50
Free moisture of Fine Aggregates = 0.40

C : FA : CA : W/C
478.95 : 524.28 : 1120.95 : 191.58
1 : 1.095 : 2.34 : 0.40
 TABLE SHOWING DIFFERENT MIX PROPORTIONS

Fly ash (%) 0 40 45 50 55 60 65

Cement 479 287.4 311.35 239.5 215.55 191.6 167.65

content
(kg/m3)

Fly
0 191.6 215.55 239.5 263.45 287.4 311.35
ash(kg/m3)

Water(kg/m3)
191.58 191.58 191.58 191.58 191.58 191.58 191.58

Water/Binder 0.40 0.40 0.40 0.40 0.40 0.40 0.40

ratio

Fine
524.28 524.28 524.28 524.28 524.28 524.28 524.28
aggregate
(kg/m3)

Coarse
1120.95 1120.95 1120.95 1120.95 1120.95 1120.95 1120.95
aggregate
(kg/m3)

Super
1.6 1.6 1.6 1.6 1.6 1.6 1.6
plasticizer
(%)
 FLY ASH
5-10% replacement older Cause for usage
concept  Environmental pollution
20-30%replacement commercial is avoided
in cement industries  Reduces co2 content in
Now a days 50-60% atmosphere by reducing
replacement High Volume production of cement
Fly Ash concrete (HVFA)

Classification Class C : Lignite coal

Class F : Anthracite coal > 5% Calcium oxide
< 5% Calcium oxide cementitious and
Pozzolanic properties Pozzolanic properties
>On Fresh concrete
•Reduction in water demand for
desired slump
•Water content, bleeding and
drying shrinkage also reduced
•Reduction in temperature up to
30% by usage of fly ash

>Hardened concrete
•Texture of concrete is dense

•Decrease in gas permeability

&water permeability
•Long term strength and water
tightness improved good for under
water structures and dams
TABLE : SHOWING COMPRESSIVE STRENGTH OF DIFFERENT PERCENTAGES
OF FLY ASH CONCRETE CUBES

SL NO. PERCENTAGE OF FLYASH DAYS OF CURING AVERAGE

AND COMPRESSIVE
SUPER PLASTICIZER STRENGTH (Mpa)

7 32.40
1 CONTROLLED CUBES
SUPER PLASTICIZER=1.6% 14 50.73
W/C = 0.40
CF=0.80
28 67.50

14 29.76
2 FLY ASH =40%
SUPER PLASTICIZER=1.6% 28 36.86
W/C = 0.40
CF=0.81
56 61.49

14 25.08
3 FLY ASH =45%
SUPER PLASTICIZER=1.6% 28 33.72
W/C = 0.40
CF=0.81
56 61.92
20
CONTD……...
14 20.39
4 FLY ASH =50%
SUPER PLASTICIZER=1.6% 28 36.04
W/C = 0.40
CF=0.83 56 63.95

14 18.91
5 FLY ASH =55%
SUPER PLASTICIZER=1.6% 28 38.81
W/C = 0.40
CF=0.85 56 66.19

14 18.15
6 FLY ASH =60%
SUPER PLASTICIZER=1.6% 28 22.85
W/C = 0.40
CF=0.86 56 57.94

14 18.31
7 FLY ASH =65%
SUPER PLASTICIZER=1.6% 28 27.09
W/C = 0.40
CF=0.87 56 49.66
TABLE : SHOWING FLEXURAL STRENGTH AND MODULUS OF ELASTICITY
OF DIFFERENT PERCENTAGES OF FLY ASH CONCRETE BEAMS

SL NO. PERCENTAGE OF DAYS OF CURING AVERAGE AVERAGE

FLYASH AND FLEXURAL MODULUS OF
SUPER PLASTICIZER STRENGTH (Mpa) ELASTICITY

CONTROLLED BEAMS 7 3.98 9.97

1 SUPER
PLASTICIZER=1.6%
14 4.98 11.15
W/C = 0.40
CF=0.80
28 5.75 11.98

14 3.82 9.77
2 FLY ASH =40%
SUPER
28 4.25 10.30
PLASTICIZER=1.6%
W/C = 0.40
CF=0.81 56 5.47 11.71

14 3.50 9.35
3 FLY ASH =45%
SUPER
28 4.06 10.07
PLASTICIZER=1.6%
W/C = 0.40
CF=0.81 56 5.50 11.72
CONTD……...
14 3.15 8.87
4 FLY ASH =50%
SUPER 28 4.20 10.24
PLASTICIZER=1.6% 56 5.60 11.82
W/C = 0.40
CF=0.83

14 2.90 8.62
5 FLY ASH =55%
SUPER 28 4.36 10.47
PLASTICIZER=1.6% 56 5.69 11.92
W/C = 0.40
CF=0.85
14 2.98 8.50
6 FLY ASH =60%
SUPER 28 3.34 9.14
PLASTICIZER=1.6% 56 4.76 10.81
W/C = 0.40
CF=0.86
14 2.99 8.43
7 FLY ASH =65%
SUPER 28 3.64 9.10
PLASTICIZER=1.6% 56 4.70 10.42
W/C = 0.40
CF=0.87
TABLE : SHOWING SPLIT TENSILE STRENGTH OF DIFFERENT
PERCENTAGES OF FLY ASH CONCRETE CYLINDERS
SL NO. PERCENTAGE OF FLYASH DAYS OF CURING AVERAGE SPLIT
AND TENSILE
SUPER PLASTICIZER STRENGTH (Mpa)

7 10.30
1 CONTROLLED CYLINDERS
SUPER PLASTICIZER=1.6%
14 16.15
W/C = 0.40
CF=0.80
28 21.48

14 9.48
2 FLY ASH =40%
SUPER PLASTICIZER=1.6%
28 11.73
W/C = 0.40
CF=0.81
56 19.54

14 7.89
3 FLY ASH =45%
SUPER PLASTICIZER=1.6%
28 10.73
W/C = 0.40
CF=0.81
56 19.71
CONTD……………...
14 6.49
4 FLY ASH =50%
SUPER PLASTICIZER=1.6% 28 11.47
W/C = 0.40
CF=0.83 56 20.33

14 5.47
5 FLY ASH =55%
SUPER PLASTICIZER=1.6% 28 12.35
W/C = 0.40
CF=0.85 56 21.07

14 5.77
6 FLY ASH =60%
SUPER PLASTICIZER=1.6% 28 7.27
W/C = 0.40
CF=0.86 56 14.74

14 5.82
7 FLY ASH =65%
SUPER PLASTICIZER=1.6% 28 8.60
W/C = 0.40
CF=0.87 56 14.37
From the results of marsh cone test, it is concluded that, at saturation point,
marsh cone time in seconds for BRAND1, BRAND2, BRAND 3 and BRAND 4 are
11.6, 13.0, 13.3, and 16.0 respectively.

From this we can conclude that BRAND1 cement is more compatible with
admixture conplast SP 430, because the marsh cone time is lowest than any other
cements, when compared. Hence Ultra tech cements are used for further studies.

To achieve the mean target strength controlled concrete cubes, beams and
cylinders were casted with W/C ratio 0.4 at 1.6% of super plasticizer. Three
specimens were casted and tested for 7 days, 14 days, 28 days and compressive
strength is recorded as an average value. The workability in its green state is
measured in terms of compaction factor.

Further using this controlled mix, cubes, beams and cylinders were casted with
replacement of cement with Fly ash at 40%, 45%, 50%, 55%, 60% and 65%. In all
these case W/C ratio and super plasticizer is kept constant. The compressive
strength of concrete cubes, the flexural strength of concrete beams and split
tensile strength of cylinders were determined at 14,28,56 days, and is tabulated.
 CONTD……...
Based on the experimental results the following observations are made.
 
1. The mean target strength is achieved at cement quantity of 470 kg/m3
with W/C ratio 0.4 at super plasticizer 1.6%. 

2. For control mix the workability is measured at 1.6% super plasticizer and
compaction factor is noted as 0.80.

3. It has been observed that concrete with 55% replacement of Fly ash at 56
days curing with 1.6% super plasticizer, the maximum compressive
strength of 67.58 Mpa is obtained. The workability measured at this
stage 0.85.

4. It has been observed that concrete with 55% replacement of Fly ash at 56
days curing with 1.6% super plasticizer, the maximum flexural strength of
5.75 Mpa and modulus of elasticity 11.85 N/mm2 is obtained.
 CONTD……...

5. It has been observed that concrete with 55% replacement of

Fly ash at 56 days curing with 1.6% super plasticizer, the
maximum split tensile strength is obtained.

6. It has been observed that, with increase in percentage of

addition of Fly ash the workability also increases.

7. The rate strength developed in Fly ash concrete is slow at

early ages. It may be due to delayed Pozzolanic activity,
however at later stages the strength development increases.
From this it can be concluded that Fly ash concrete should be
cured for longer duration.

8. Fly ash concrete develops strength at lower rate and hence

the heat of hydration is also less. Hence this concrete do not
develops any thermal cracks
COLLECTION OF FLY ASH IN RAICHUR THERMAL POWER STATION

IMAGE OF
MECHANICAL MIXER
SUPER PLASTICIZER
USED FOR
CONPLAST SP 430 BY
COMPATABILITY
FOSROC CHEMICALS
PVT LTD.
CASTING OF CONCRETE CUBES CURING OF CUBES BEAMS AND
CYLINDERS

UNIVERSAL TESTING
MACHINE
LEFT TO
COMPRESSION
TESTING /
RIGHT TO FLEXURAL
TESTING MACHINE