USAGE OF FLY ASH IN CONCRETE

PROJECT REPORT

Submitted for the course: Advanced Concrete Technology (CLE 2007)

Name of the faculty: Dr S. Balamurugan

Submitted by:-
17BCL0022 SUSHANTH PREETHAM [email protected]
17BCL0058 PALURU SATHYANARAYANA [email protected]
17BCL0154 DHRUVA KUMAR REDDY BANDI [email protected]
17BCL0216 ANUSH SIRNAPALLY [email protected]

NOVEMBER 2018
Fall Semester- 2018-2019
 CERTIFICATE

This is to certify that the project work entitled “USAGE OF FLY ASH IN
CONCRETE AND ITS DURABILITY STUDY’’ that is being submitted by
“SUSHANTH PREETHAM,PALURU SATHYANARAYANA, DHRUVA KUMAR REDDY
BANDI, ANUSH SIRNAPALLY” for is a record of bonafide work done under my
supervision. The contents of this Project work, in full or in parts; neither taken
from any other source nor submitted for any other CAL course.
Place: Vellore
Date: 13-11-2018

Signature of Faculty:

Dr S. BALAMURUGAN
 ABSTRACT

This project work performed to study the compressive strength behaviour of the concrete
cubes; these cubes were replaced with fly ash 20%, 30% and 40% respectively.
The compressive strengths of the cubes studied at 7 days and 28 days in the laboratory.
Standard codebooks and guidelines have been followed while performing the tests and
through the project. Compressive strengths are plotted in graph, for early strength and
target strength, 30% replacement is optimal.
OBJECTIVE
The main objective of this project work is to study the effect of
processed fly ash, used as partial substitute for cement, on the
performance of cement with normal river sand available locally. This
study involves the replacement levels of fly ash to cement at 20%, 30%
and 40% for proportion. Casted cubes were tested for compressive
strength at 7 and 28 days.

INTODUCTION
We have to realise the increasing demand for river sand supply in
construction sector, which has put a lot of burden on this natural
resources, our aim, is to find alternative material to reduce the use of
natural sand in concrete production. The existence of fly ash, a by-
product generated from coal power plant, which pose negative impact
to the environment when it is disposed as waste can be used as partial
were used in this research.
The use of fly ash in Portland cement concrete (PCC) has many
benefits and improves concrete performance in both the fresh and
hardened state. Fly ash use in concrete improves the workability of
plastic concrete, and the strength and durability of hardened
concrete. Fly ash use is also cost effective. When fly ash is added to
concrete, the amount of Portland cement may be reduced.
Rihand Dam, also known as Govind Ballabh Pant Sagar, is India's
largest artificial lake. In India, fly ash was used for the first time in the
construction of Rihand Irrigation Project, Uttar Pradesh in
1962,replacing cement upto about 15 per cent.
Fig: Rihand Dam

FLY ASH PRODUCTION and its AVAILABILITY

Indian coal is of low grade with ash content of the order of 30-45 % in
comparison to imported coals which have low ash content of the order
of 10-15%. Large quantity of ash is, thus being generated at
coal/lignite based Thermal Power Stations in the country, which not
only requires large area of precious land for its disposal but is also one
of the sources of pollution of both air and water. ( Source: NTPC)

Table : Fly Ash production and Utilisation in the 1st half of the year 2016-17, 2017-18.
 Fig: Major Modes of Fly Ash Utilisation in the 1st half of the year 2017-18.

USES of FLY ASH

1. Concrete production, as a substitute material for Portland cement,
sand.
2. Fly-ash pellets which can replace normal aggregate in concrete
mixture.
3. Embankments and other structural fills (usually for road
construction).
4. Waste stabilization and solidification.
5. Cement clinker production - (as a substitute material for clay).
6. Mine reclamation.
7. Stabilization of soft soils.
8. Road subbase construction.
9. As aggregate substitute material (e.g. for brick production).
10. Mineral filler in asphaltic concrete.
11. Loose application on rivers to melt ice.
12. Loose application on roads and parking lots for ice control.
BENEFITS of FLY ASH
1. Produces denser concrete and a smoother surface with sharper
detail.
2. Great workability.
3. Reduces crack problems, permeability, and bleeding
4. Reduces heat of hydration.
5. Produces lower water/cement ratio for similar slumps when
compared to no fly ash mixes.
6. Reduces CO2 emissions.
7. The increase in creep with fly ash content upto 15% is negligible.
8. Increases the modulus of elasticity of concrete when concretes of
the same strength with and without fly ash are compared.
9. Improved sulphate resistance.
10. Lower water and air permeability.
11. Lower leaching of lime liberated during hydrated of cement.
12. Greater resistance to attack of aggressive waters.
HOW FLY ASH WORKS WITH CEMENT IN CONCRTE?
Ordinary Portland Cement (OPC) is a product of four principal
mineralogical phases. These phases are Tricalcium Silicate- C S
(3CaO.SiO ), Dicalcium Silicate C S (2CaO.SiO ), Tricalcium Aluminate-
C A (3CaO.Al O ) and Tetracalcium alumino-ferrite - C AF(4CaO. Al O Fe
O ). The setting and hardening of the OPC takes place as a result of
reaction between these principal compounds and water. The reaction
between these compounds and water are shown as under:

The hydration rod s from CS and CS are similar but quantity of calcium
hydroxide (lime) released is higher in C S as compared to CS .
The reaction of C A with water takes place in presence of sulphate ions
supplied by dissolution of gypsum present in OPC. This reaction is very
fast and is shown as under:

Tetracalcium alumino-ferrite forms hydration product similar to those

of C A, with iron substituting partially for alumina in the crystal
structures of ettringite and monosulpho-aluminate hydrate.
Above reactions indicate that during the hydration process of cement,
lime is released out and remains as surplus in the hydrated cement.
This leached out surplus lime renders deleterious effect to concrete
such as make the concrete porous, give chance to the development of
micro- cracks, weakening the bond with aggregates and thus affect
the durability of concrete.
If fly ash is available in the mix, this surplus lime becomes the source
for pozzolanic reaction with fly ash and forms additional C-S-H gel
having similar binding properties in the concrete as those produced by
hydration ofcement paste. The reaction of fly ash with surplus lime
continues as long as lime is present in the pores of liquid cement
paste.

MATERIALS
1. CEMENT
Ordinary Portland cement conforming to IS: 8112-1939( M 43 Grade)
or IS 12269 : 2013 ( M 53 Grade) will be used. Standard sand for use
in the tests shall conform to IS : 650-196611.

2. Sand (IS 650 : 1991)

The standard sand shall be of quartz, light grey or whitish variety and
shall be free from silt. The sand grains shall be angular, the shape of
the grains approximating to the spherical form; elongated and
flattened grains being present only in very small or negligible
,quantities. The standard sand shall (100 percent) pass through 2-ml11
IS sieve and shall be ( 100 percent ) retained on 90-micron IS Sieve.
The standard sand shall be free from organic impurities. Standard
sand for use in the tests shall conform to IS : 650-196611.
3. FLY ASH (IS 3812 part 1: 2003)
Fly ash is finely divided residue resulting from the combustion of
powdered coal and transported by the flue gases and collected by
electrostatic precipitator. Fly ash is the most widely used pozzolanic
material all over the world. In the recent time, the importance and use
of fly ash in concrete has grown so much that it has almost become a
common ingredient in concrete, particularly for making high strength
and high performance concrete. Extensive research has been done all
over the world on the benefits that could be accrued in the utilisation
of fly ash as a supplementary cementitious material. High volume fly
ash concrete is a subject of current interest all over the world.
The use of fly ash as concrete admixture not only extends technical
advantages to the properties of concrete but also contributes to the
environmental pollution control. In India alone, we produce about 75
million tons of fly ash per year, the disposal of which has become a
serious environmental problem. The effective utilisation of fly ash in
concrete making is, therefore, attracting serious considerations of
concrete technologists and government departments. In India, the
total production of fly ash is nearly as much as that of cement (75
million tons). But our utilisation of fly ash is only about 5% of the
production. Therefore, the use of fly ash must be popularised for more
than one reasons.
Class F: The burning of harder, older anthracite and bituminous coal
typically produces Class F fly ash. This fly ash is pozzolanic in nature,
and contains less than 5% lime (CaO). Possessing pozzolanic
properties, the glassy silica and alumina of Class F fly ash requires a
cementing agent, such as Portland cement, quicklime or hydrated lime
mixed with water to react and produce cementations compounds.
Alternatively, adding a chemical activator such as sodium
silicate(water glass) to a Class F ash can form a geopolymer.
Class C: Fly ash produced from the burning of younger lignite or sub-
bituminous coal, in addition to having pozzolanic properties, also has
some self-cementing properties. In the presence of water, Class C fly
ash hardens and gets stronger over time. Class C fly ash generally
contains more than 20% lime (CaO). Unlike Class F, self-cementing
Class C fly ash does not require an activator. Alkali and sulphate (SO4)
contents are generally higher in Class C fly ashes. fly ash is a
heterogeneous material. SiO2, Al2O3, Fe2O3 and occasionally CaO are
the main chemical components present in fly ashes. The mineralogy
of fly ashes is very diverse. The main phases encountered are a glass
phase, together with quartz, mullite and the iron oxide hematite
magnetite and maghemitit. Other phases often identified are
cristobalite, anhydrite, free lime, periclase, calcitie, sylvite, halite,
portlandite, rutile and anatase. The Ca-bearing minerals anorthite,
gehlenite, akermanite and various calcium silicates and calcium
aluminates identical to those found in Portland cement can be
identified in Ca-rich fly ashes.

Table : Percentage of Oxides in various types Coal.

TESTS PERFORMED
1. Specific Gravity of Cement - IS 2720 (Part-3)
Apparatus:
(a) Le Chaterlier’s Flask
Le Chaterlier”s flask, is made of thin glass having a bulb at the
bottom. The capacity of the bulb is nearly 250 ml. The bulb is 7.8 cm
in mean diameter. The stem is graduated in millimeters.
(b) Weighing Balance
(c) Kerosene

Procedure:
(I) Dry the flask carefully and fill with kerosene or naphtha to a point
on the stem between zero and
1 ml.
(II) Record the level of the liquid in the flask as initial reading.
(III) Put a weighted quantity of cement (about 60 gm) into the flask so
that level of kerosene rise to about 22 ml mark, care being taken to
avoid splashing and to see that cement does not adhere to the sides
of the above the liquid.
(IV) After putting all the cement to the flask, roll the flask gently in an
inclined position to expel air until no further air bubble rises to the
surface of the liquid.
(V) Note down the new liquid level as final reading.
(vi) Specific gravity of cement is given by cement consumed (X) / 10 x
weight of kerosene (0.83).
Observation and Calculations:
Initial weight of the cement taken = 100 g
Weight of the remaining cement = 73 g
Amount of kerosene taken = 90 ml
Cement consumed = 100 – 73 = 2 g
Specific gravity = X/10 x 0.83
= 27 g / 10 x 0.83
= 3.25 g/cc
Specific gravity of a sample of cement = 3.25 g/cc

2. Specific Gravity of FLY ASH-IS: 3812-1981

Apparatus:
(a) Le Chaterlier’s Flask
Le Chaterlier”s flask, is made of thin glass having a bulb at the
bottom. The capacity of the bulb is nearly 250 ml. The bulb is 7.8 cm
in mean diameter. The stem is graduated in millimeters.
(b) Weighing Balance
(c) Kerosene

Procedure
(I) Dry the flask carefully and fill with kerosene or naphtha to a point
on the stem between zero and 1 ml.
(II) Record the level of the liquid in the flask as initial reading.
(III) Put a weighted quantity of Fly Ash(about 60 gm) into the flask so
that level of kerosene rise to about 22 ml mark, care being taken to
avoid splashing and to see that cement does not adhere to the sides
of the above the liquid.
(IV) After putting all the Fly Ash to the flask, roll the flask gently in an
inclined position to expel air until no further air bubble rises to the
surface of the liquid.
(V) Note down the new liquid level as final reading.
(vi) Specific gravity of Fly Ash is given by Fly Ash consumed (X) / 10 x
weight of kerosene (0.83).

Observations and Calculations

Initial weight of the Fly Ash taken = 70 g
Weight of the remaining Fly Ash = 53 g
Amount of kerosene taken = 90 ml
Fly Ash consumed = 70 –53= 17 g
Specific gravity = X/10 x 0.83
= 17 g / 10 x 0.83
= 2.16g/cc
Specific gravity of a sample of Fly Ash = 2.16 g/cc
MIX DESIGN CALCULATIONS

1. 20% REPLACEMENT OF CEMENT WITH FLY ASH

STIPULATIONS FOR PROPORTIONING

Grade designation M40

Type of cement OPC 43 grade conforming to IS 8112
Type of mineral admixture Fly ash conforming to IS 38I2 (Part I)
Maximum nominal size of aggregate 12.5mm
Minimum cement content 360 kg/m'
Maximum water-cement ratio 0.40
Workability 125 mm (slump)
Exposure condition Severe (for reinforced concrete)
Degree of supervision Good
Type of aggregate Crushed angular aggregate
Maximum cement (OPC) content 450 kg/m'

TEST DATA FOR MATERIALS

Cement used OPC 43 grade conforming to IS 8112
Specific gravity of cement 3.25
Fly ash Conforming to IS 3812 (Part I)
Specific gravity of fly ash 2.16
Specific gravity of:
I) Coarse aggregate 2.74
2) Fine aggregate 2.74

TARGET STRENGTH FOR MIX PROPORTIONING

f‘ck=fck + 1.65 s
where
f‘ck = target average compressive strength at 28 days.
fck = characteristics compressive strength at 28 days.
s = standard deviation.
From Table I, Standard Deviation, s = 5 N/mm2.
Therefore, target strength = 40 + 1.65 x 5 = 48.25 N/mm2.
SELECTION OF WATER-CEMENT RATIO

From Table 5 of IS 456, maximum water-cement ratio = 0.40

SELECTION OF WATER CONTENT

From Table 2, maximum water content for 12 .5mm aggregate = 202.5 liter (for 25 to 50 mm
slump range)
Estimated water content for 125 mm slump= 202.5+ (9/125)*202.5
=217.08 liter
CALCULATION OF CEMENT AND FLY ASH CONTENT

Water-cement ratio (see note under 4.1)

Cementitious material (cement + fly ash) content = 217.08/0.40
= 542.7
From Table 5 of IS 456, minimum cement content for 'severe' exposure conditions
350 kg/m3 > 320 kg/m3, hence OK.
Now, to proportion a mix containing fly ash the following steps are suggested:

a) Decide the percentage fly ash to be used based on project requirement and quality of
materials

b) In certain situations increase in cernentitious material content may be warranted, The

decision on increase in cementitious material content and its percentage may be based on
experience and trial (see Note),

NOTE - This illustrative example is with increase of 10 percent cementitious material

content.
Cementitious material content Water Content= 542.7*1/10=596.95 kg/m3
So water-cement ratio=217.08/596.95
=0.36
Fly ash @ 20% of total cementitious material content= 596.95 x 20% =120 kg/m 3
Cement (OPC) = 596.95-120=447 kg/m3
Fly ash being utilized = 120 kg/m3
PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE
CONTENT

From Table 3, volume of coarse aggregate corresponding to 12.5 mm size aggregate and fine
aggregate (Zone I) for water-cement ratio of 0.40 =0.50
In the present case water-cement ratio is 0.40, Therefore volume of coarse aggregate is
required to be increased to decrease the line aggregate content. As the water-cement ratio
is lower by 0.10 the proportion of volume of coarse aggregate is increased by 0.02 (at the
rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio),Therefore corrected
proportion of volume of coarse aggregate for the water-cement ratio of 0.40 = 0.52
Therefore volume of coarse aggregate =0.52
Volume of fine aggregate content = 1 - 0.52 = 0.48
MIX CALCULATIONS

The mix calculations per unit volume of concrete shall be as follows:

a)Volume of concrete = 1 m3
b) Volume of cement
= Mass of cement /Specific gravity of cement*1/ 1000
=0.477/3.25*1/1000
=0.146 m3
c) Volume of fly ash=Mass of fly ash/Specific gravity of fly ash*1/1000
=120/2.16*1/1000
=0.056 m3
d) Volume of water=Mass of water /Specific gravity of water* 1/1000
=217.08/10*1/1000
=0.217 m3
e) Volume of all in aggregate= [a - (b + c + d)]
= [1-(0.146+0.056+0.217)]
= 0.581
f) Mass of coarse aggregate= e x volume of coarse aggregate x Specific gravity of coarse
aggregate x1000
=0.581*0.52*2.74*1000
=828 kg
g) Mass of fine aggregate= e x volume of fine aggregate x Specific gravity of fine aggregate x
1000
=0.581*0.48*2.74*1000
=764.13 kg
MIX PROPORTIONS

Cement = 447 kg/m3

Fly Ash = 120 kg/m3
Water = 217.08 kg/m3
Fine aggregate = 764.13 kg/m3
Coarse aggregate = 828 kg/m3

2. 30% REPLACEMENT OF CEMENT WITH FLY ASH

STIPULATIONS FOR PROPORTIONING

Grade designation M40

Type of cement OPC 43 grade conforming to IS 8112
Type of mineral admixture Fly ash conforming to IS 38I2 (Part I)
Maximum nominal size of aggregate 12.5mm
Minimum cement content 360 kg/m'
Maximum water-cement ratio 0.40
Workability 125 mm (slump)
Exposure condition Severe (for reinforced concrete)
Degree of supervision Good
Type of aggregate Crushed angular aggregate
Maximum cement (OPC) content 450 kg/m'

TEST DATA FOR MATERIALS

Cement used OPC 43 grade conforming to IS 8112
Specific gravity of cement 3.25
Fly ash Conforming to IS 3812 (Part I)
Specific gravity of fly ash 2.16
Specific gravity of:
I) Coarse aggregate 2.74
2) Fine aggregate 2.74

TARGET STRENGTH FOR MIX PROPORTIONING

f‘ck=fck + 1.65 s
where
f‘ck = target average compressive strength at 28 days.
fck = characteristics compressive strength at 28 days.
s = standard deviation.
From Table I, Standard Deviation, s = 5 N/mm2.
Therefore, target strength = 40 + 1.65 x 5 = 48.25 N/mm2.
SELECTION OF WATER-CEMENT RATIO

From Table 5 of IS 456, maximum water-cement ratio (see Note under 4.1) = 0.40
SELECTION OF WATER CONTENT

From Table 2, maximum water content for 12 .5mm aggregate = 202.5 liter (for 25 to 50 mm
slump range)
Estimated water content for 125 mm slump= 202.5+ (9/125)*202.5 = 217.08 liter
CALCULATION OF CEMENT AND FLY ASH CONTENT

Water-cement ratio (see note under 4.1)

Cementitious material (cement + fly ash) content = 217.08/0.40 = 542.7
From Table 5 of IS 456, minimum cement content for 'severe' exposure conditions
350 kg/m3 > 320 kg/m3, hence OK.
Now, to proportion a mix containing fly ash the following steps are suggested:
a) Decide the percentage fly ash to be used based on proje ct requirement and quality of
mater ials
b) In certain situations increase in cernentitious material content may be warranted, The
decision on increase in cementitious material content and its percentage may be based on
experience and trial (see Note),
NOTE - This illustrative example is with increase of 10 percent cementitious material
content.
Cementitious material content Water Content= 542.7*1/10=596.95 kg/m3
So water-cement ratio=217.08/596.95 = 0.36
Fly ash @ 30% of total cementitious material content= 596.95 x 30% =179.08 kg/m 3
Cement (OPC) = 596.95-179.08=417.87 kg/m3
Fly ash being utilized = 179.08 kg/m3

PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE

CONTENT

From Table 3, volume of coarse aggregate corresponding to 12.5 mm size aggregate and fine
aggregate (Zone I) for water-cement ratio of 0.40 =0.50
In the present case water-cement ratio is 0.40, Therefore volume of coarse aggregate is
required to be increased to decrease the line aggregate content. As the water-cement ratio
is lower by 0.10 the proportion of volume of coarse aggregate is increased by 0.02 (at the
rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio),Therefore corrected
proportion of volume of coarse aggregate for the water-cement ratio of 0.40 = 0.52
Therefore volume of coarse aggregate =0.52
Volume of fine aggregate content = 1 - 0.52 = 0.48
MIX CALCULATIONS

The mix calculations per unit volume of concrete shall be as follows:

a) Volume of concrete = 1 m3
b) Volume of cement
= Mass of cement /Specific gravity of cement*1/ 1000
=0.417/3.25*1/1000
=0.128 m3
c) Volume of fly ash=Mass of fly ash/Specific gravity of fly ash*1/1000
=179.08/2.16*1/1000
=0.082 m3
d) Volume of water=Mass of water /Specific gravity of water* 1/1000
=217.08/10*1/1000
=0.217 m3
e) Volume of all in aggregate= [a - (b + c + d )]
= [1-(0.128+0.082+0.217)]
= 0.573
f) Mass of coarse aggregate= e x volume of coarse aggregate x Specific gravity of coarse
aggregate x1000
=0.573*0.52*2.74*1000
=816.41kg
g) Mass of fine aggregate= e x volume of fine aggregate x Specific gravity of fine aggregate x
1000
=0.573*0.48*2.74*1000
=753.60 kg
MIX PROPORTIONS

Cement = 417.87 kg/m3

Fly Ash = 179.08 kg/m3
Water = 217.08 kg/m3
Fine aggregate = 753.60 kg/m3
Coarse aggregate = 816.4 kg/m3

3. 40% REPLACEMENT OF CEMENT WITH FLY ASH

STIPULATIONS FOR PROPORTIONING

Grade designation M40

Type of cement OPC 43 grade conforming to IS 8112
Type of mineral admixture Fly ash conforming to IS 38I2 (Part I)
Maximum nominal size of aggregate 12.5mm
Minimum cement content 360 kg/m'
Maximum water-cement ratio 0.40
Workability 125 mm (slump)
Exposure condition Severe (for reinforced concrete)
Degree of supervision Good
Type of aggregate Crushed angular aggregate
Maximum cement (OPC) content 450 kg/m'

TEST DATA FOR MATERIALS

Cement used OPC 43 grade conforming to IS 8112
Specific gravity of cement 3.25
Fly ash Conforming to IS 3812 (Part I)
Specific gravity of fly ash 2.16
Specific gravity of:
I) Coarse aggregate 2.74
2) Fine aggregate 2.74

TARGET STRENGTH FOR MIX PROPORTIONING

f‘ck=fck + 1.65 s
where
f‘ck = target average compressive strength at 28 days.
fck = characteristics compressive strength at 28 days.
s = standard deviation.
From Table I, Standard Deviation, s = 5 N/mm2.
Therefore, target strength = 40 + 1.65 x 5 = 48.25 N/mm2.
SELECTION OF WATER-CEMENT RATIO

From Table 5 of IS 456, maximum water-cement ratio (see Note under 4.1) = 0.40
SELECTION OF WATER CONTENT

From Table 2, maximum water content for 12 .5mm aggregate = 202.5 liter (for 25 to 50 mm
slump range)
Estimated water content for 125 mm slump= 202.5+ (9/125)*202.5 = 217.08 liter
CALCULATION OF CEMENT AND FLY ASH CONTENT

Water-cement ratio (see note under 4.1)

Cementitious material (cement + fly ash) content = 217.08/0.40 = 542.7
From Table 5 of IS 456, minimum cement content for 'severe' exposure conditions
350 kg/m3 > 320 kg/m3, hence OK.
Now, to proportion a mix containing fly ash the following steps are suggested:
a) Decide the percentage fly ash to be used based on project requirement and quality of
materials
b) In certain situations increase in cementitious material content may be warranted, The
decision on increase in cementitious material content and its percentage may be based on
experience and trial (see Note),
NOTE - This illustrative example is with increase of 10 percent cementitious material
content.
Cementitious material content Water Content= 542.7*1/10=596.95 kg/m3
So water-cement ratio=217.08/596.9 = 0.36
Fly ash @ 30% of total cementitious material content= 596.95 x 40% =238.8 kg/m 3
Cement (OPC) = 596.95-238.8=358 kg/m3
Fly ash being utilized = 238.8 kg/m3
PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE
CONTENT

From Table 3, volume of coarse aggregate corresponding to 12.5 mm size aggregate and fine
aggregate (Zone I) for water-cement ratio of 0.40 =0.50

In the present case water-cement ratio is 0.40, Therefore volume of coarse aggregate is
required to be increased to decrease the line aggregate content. As the water-cement ratio
is lower by 0.10 the proportion of volume of coarse aggregate is increased by 0.02 (at the
rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio),Therefore corrected
proportion of volume of coarse aggregate for the water-cement ratio of 0.40 = 0.52
Therefore volume of coarse aggregate =0.52
Volume of fine aggregate content = 1 - 0.52 = 0.48
MIX CALCULATIONS

The mix calculations per unit volume of concrete shall be as follows:

a) Volume of concrete = 1 m3
b) Volume of cement
= Mass of cement /Specific gravity of cement*1/ 1000
=0.358/3.25*1/1000
=0.110 m3
c) Volume of fly ash=Mass of fly ash/Specific gravity of fly ash*1/1000
=238.8/2.16*1/1000
=0.110 m3
d) Volume of water=Mass of water /Specific gravity of water* 1/1000
=217.08/10*1/1000
=0.217 m3
e) Volume of all in aggregate= [a - (b + c + d)]
= [1-(0.110+0.110+0.217)]
= 0.563
f) Mass of coarse aggregate= e x volume of coarse aggregate x Specific gravity of coarse
aggregate x1000
=0.563*0.52*2.74*1000
=802.62kg
g) Mass of fine aggregate= e x volume of fine aggregate x Specific gravity of fine aggregate x
1000
=0.563*0.48*2.74*1000 =740.45 kg
MIX PROPORTIONS

Cement = 358 kg/m3

Fly Ash = 240 kg/m3
Water = 217.08 kg/m3
Fine aggregate = 741 kg/m3
Coarse aggregate = 803 kg/m3
 OBSERVATIONS
1. 7 days compressive strength
(a) 20%
S.No Age of Cross Load (N) Compressive Average
Cube Sectional Strength Compressive
Area (mm2) (KN/mm2) Strength(MPa)

1 7 Days 4900 96 19.5

2 7 Days 4900 105 21.5 20.3

3 7 Days 4900 98 20
(b) 30%
S.No Age of Cube Cross Load (N) Compressive Average
Sectional Strength Compressive
Area (mm2) (KN/mm2) Strength(MPa)

1 7 Days 4900 137 27.9 26.5

2 7 Days 4900 124 25.3

3 7 Days 4900 130 26.5

(c) 40%
S.No Age of Cube Cross Load (N) Compressive Average
Sectional Strength Compressive
Area (mm2) (KN/mm2) Strength(MPa)

1 7 Days 4900 96 19.5

2 7 Days 4900 95 19.3 18.3

3 7 Days 4900 80 16.3

 2. 28 days compressive strength
(a) 20%
S.No Age of Cube Cross Load (N) Compressive Average
Sectional Strength Compressive
Area (KN/mm2) Strength(MPa)
(mm2)

1 28 Days 4900 189 38.5

2 28 Days 4900 197 40.2 40.2

3 28 Days 4900 206 42

(b) 30%
S.No Age of Cube Cross Load (N) Compressive Average
Sectional Strength Compressive
Area (KN/mm2) Strength(MPa)
(mm2)

1 28 Days 4900 215 43.8

2 28 Days 4900 219 44.6 43.53

3 28 Days 4900 207 42.2

(c) 40%
S.No Age of Cube Cross Load (N) Compressive Average
Sectional Strength Compressive
Area (KN/mm2) Strength(MPa)
(mm2)

1 28 Days 4900 169 34.4 35.3

2 28 Days 4900 178 36.3

3 28 Days 4900 173 35.3

 Fig: Graph representing Compressive strength VS % replacement of fly ash, Blue bar
indicates the compressive strength at 7 days and orange represents compressive strength at 28
days with 20%, 30% and 40% replacements respectively.

RESULT
From the above Bar graph we can conclude that the 30%
replacement of cement with fly ash is optimal.