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Experimental studies on partial replacement of cement with fly ash in

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Article in International Journal of Civil Engineering and Technology · September 2017

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International Journal of Civil Engineering and Technology (IJCIET)
Volume 8, Issue 9, September 2017, pp. 293–298, Article ID: IJCIET_08_09_034
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ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

EXPERIMENTAL STUDIES ON PARTIAL

REPLACEMENT OF CEMENT WITH FLY ASH
IN CONCRETE ELEMENTS
K.V. Sabarish, BE., M.Tech.,(P.hd)
Assistant Professor, Department of Civil Engineering,
Vels University, Tamil Nadu, India

R. Venkat Raman, R. Ancil, R. Wasim Raja, P. Selva Surendar

Students, Department of Civil Engineering,
Vels University, Tamil Nadu, India

ABSTRACT
In today’s world the main emphasis is on green and sustainable development.
Presently large amount of fly ash is generated in thermal power plants as a waste
material with an improper impact on environment and humans. Fly ash a waste
generated by thermal power plants is as such a big environmental concern. The
experimental studies on mortar containing fly ash as a partial replacement of sand by
weight as well as by volume were carried out to quantify its utilization. Both the types
of pond and bottom fly ash in various ratios were used in preparing cement mortar
and their strengths in compression and tension were tested. The use of fly ash in
concrete formulations as a supplementary cementatious material was tested as an
alternative to traditional concrete. The cement has been replaced by fly ash
accordingly in the range of 0% (without fly ash), 10%, 20%, 30% & 40% by weight of
cement for M-25 and M-40 mix. These tests were carried out to evaluate the
mechanical properties for the test results for compressive strength up to 28 days and
split strength for 56 days are taken.
Key words: Fly Ash, Compressive Strength, Split Strength, Thermal Industry Waste.
Cite this Article: K.V. Sabarish, R. Venkat Raman, R. Ancil, R. Wasim Raja, P. Selva
Surendar, Experimental Studies on Partial Replacement of Cement with Fly Ash in
Concrete Elements. International Journal of Civil Engineering and Technology, 8(9),
2017, pp. 293–298.
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1. INTRODUCTION
In India now a days, the concept of smart city is growing very faster. As the main emphasis is
on green and sustainable development. Infrastructure is the basic arm and smart material is
essential to achieve that feat properly. Smart material is a one which gives better results in
low economy. These industrial wastes are dumped in the nearby land and the natural fertility

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 K.V. Sabarish, R. Venkat Raman, R.Ancil, R. Wasim Raja, P. Selva Surendar

of the soil is spoiled. Fly ash is the finely divided mineral residue resulting from the
combustion of ground or powdered coal in electric power generating thermal plant. Fly ash is
a beneficial mineral admixture for concrete. Fly ash is a by-product produced from the
combustion of coal in an electrical generation station. According to Design and Control of
Concrete Mixtures (2010). Fly ash is a natural pozzolan, which means that it is a “siliceous or
siliceous-and-aluminous material” which chemically reacts with calcium hydroxide (CH) to
form composites having cementitous properties It influences many properties of concrete in
both fresh and hardened state. Cement Industry is major in contributor in the emission of CO2
as well as using up high levels of energy resources in the production of cement. By replacing
cement with a material of pozzolanic characteristic, such as the fly ash, the cement and the
concrete industry together can meet the growing demand in the construction industry as well
as help in reducing the environmental pollution. In general mortar is a mixture of cement, fine
aggregate and water, in which, coarse aggregate is avoided. Although it is possible to obtain
advantages of using fly ash in mortar as in concrete, limited research has been done in fly ash
mortars. In the present experimental investigation the fly ash has been used to study the effect
on compressive and split strength on M25 and M40 grades of concrete.

2. DESIGN MIX MATERIALS

2.1. Cementitious Material: Fly Ash
Fly ash is composed of the non-combustible mineral portion of coal. Fly ash is one of the
residues generated in combustion, and comprises the fine particles that rise with the flue
gases. Ash which does not rise is termed bottom ash. In an industrial context, fly ash usually
refers to ash produced during combustion of coal. In some cases, such as the burning of solid
waste to create electricity , the fly ash may contain higher levels of contaminants than the
bottom ash and mixing the fly and bottom ash together brings the proportional levels of
contaminants within the range to qualify as nonhazardous waste in a given state, whereas,
unmixed, the fly ash would be within the range to qualify as hazardous waste.

Figure 1 Fly Ash

Cement: Ordinary Portland cement (Ultra-Tech Cements of 53 grades) was used having
specific gravity: 3.15, 32.5% Consistency and Compressive strength 54 MPa
Table 1.Properties of Cement (OPC 53 grade)
Sr.No Physical Properties Of Cement Result Requirement As Per
Is:8112-1989
1 Specific Gravity 3.15 3.10-3.15
2 Standard Consistency (%) 28% 30-35
3 Initial Setting Time ( Hours,Min) 35 Min 30 Minimum
4 Final Setting Time ( Hours,Min) 178 Min 600 Maximum
5 Compressive Strength-7 Days 38.49 N/Mm2 43 N/Mm2
2
6 Compressive Strength -28 Days 52.31 N/Mm 53 N/Mm2

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 Experimental Studies on Partial Replacement of Cement with Fly Ash in Concrete Elements

Fine Aggregate: Natural sand with maximum size of 4.75 mm was used (zone II) with
specific gravity 2.6 and fineness modulus 2.63.

Figure 2 Fine aggregate

Coarse Aggregate: Natural aggregates with maximum size of 40 mm were used with specific
gravity of 2.7 and fine modulus 7.51.

Figure 3 Coarse aggregate

Table 2 Properties of Aggregates

Coarse Aggregate
Property Fine Aggregate
20 Mm 10 Mm
Fineness Modulus 3.35 7.54 3.19
Specific Gravity 2.38 2.76 2.69
Water Absorption (%) 1.20 1.83 1.35
Bulk Density (Gm/Cc) 1753 1741 1711

Water: Drinking water from VELS UNIVERSITY was used for the preparation of concrete.
The water samples are potable and of uniform quality.PH value should be less than 7. Water
is an important ingredient of concrete as it actually participates in the chemical reaction with
cement.

3. DESIGN MIX METHODOLOGY

3.1. Design Mix
A mix M25 & M40 grade was designed as per IS 10262:2009 and the same was used to
prepare the test samples.

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 K.V. Sabarish, R. Venkat Raman, R.Ancil, R. Wasim Raja, P. Selva Surendar

Table 3 Concrete Design Mix Proportions

S.No Concrete Concrete Design Mix Proportion (By Weight) Cement
Type W/C Ratio C F.A C.A Replacement By Fly
Ash
1 A1-M25 0.40 1.00 1.01 2.50 -
2 A2-M40 0.30 1.00 0.44 2.17 -
3 B1-M25 0.40 0.90 1.01 2.50 0.10
4 B2-M25 0.40 0.80 1.01 2.50 0.20
5 B3-M25 0.40 0.70 1.01 2.50 0.30
6 B4-M25 0.40 0.60 1.01 2.50 0.40
7 B5-M40 0.30 0.90 0.44 2.17 0.10
8 B6-M40 0.30 0.80 0.44 2.17 0.20
9 B7-M40 0.30 0.70 0.44 2.17 0.30
10 B8-M40 0.30 0.60 0.44 2.17 0.40

3.2. Compression & Split Test

Standard metallic cube moulds (150*150*150 mm) were casted for compressive and split
strength. A table vibrator was used for compaction of the hand filled concrete cubes.

Figure 4 Compressive strength testing

The specimens were demoulded after 24 hours and subsequently immersed in water for
different age of testing. For each age three specimens were tested for the determination of
average compressive and split strength. Test was performed on compression testing machine
having capacity of 200 MT. figure 6 & 7 show compressive and split strength testing setup on
testing machine.

Figure 5 Split strength testing

4. RESULTS
The compressive strength results are compiled in Table-4 and split strength in Table-5. The
compressive strength vs % replacements of cement results are graphically shown in figure 8
and 9. The same for split strength is in figure 9. 28 days for M25 & M4

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 Experimental Studies on Partial Replacement of Cement with Fly Ash in Concrete Elements

Table 4 Compressive Strength and % Change of Strength at 7, 14, 28 days for M25 & M40

Concrete Concrete Average ultimate compressive % change in compressive

grade type strength at strength at
7 days 14 days 28 days 7 days 14 days 28 days
(N/mm2) (N/mm2) (N/mm2)
A1-M25 28.77 32.00 44.59 0 0 0
B1-M25 21.33 30.96 34.67 25.86 3.35 22.24
M 25 B2-M25 16.15 23.70 24.30 43.86 25.93 45.50
B3-M25 13.04 15.11 22.22 54.67 52.78 50.16
B4-M25 9.93 14.81 17.33 65.48 53.71 61.13
A2-M40 34.81 49.04 52.74 0 0 0
B5-M40 29.33 34.93 38.22 15.74 28.77 27.53
M 40 B6-M40 13.78 27.26 27.56 60.41 44.41 47.74
B7-M40 13.04 18.37 21.48 62.53 48.66 59.27
B8-M40 8.59 13.48 20.00 75.32 72.51 62.07

Table 5 Split Strength and % Change of Strength at 56 days for M25 & M40

Concrete type Average spilt strength for % change in split

cube @56 days N/MM2 strength @56 days
A1-M25 3.44 2.32
B1-M25 3.52 -6.68
B2-M25 3.21 -25.87
B3-M25 2.55 -29.94
B4-M25 2.41 0
A2-M40 3.96 3.50
B5-M40 4.10 -29.79
B6-M40 2.78 -32.07
B7-M40 2.69 -32.07
B8-M40 2.04 -48.48

Table 6 Materials for designed M25 & M40 concrete

Materials Total %
%
Concrete Cement Fine Coarse Grit Fly Ash Cost (M3) Change
Reduction
Grade (Kg/M3) Aggregate Aggregate (Kg/M3) (Kg/M3) In Cost
In Cement
(Kg/M3) (Kg/M3)
M 25 0 479 485.75 718.22 478.81 0 4135.12 0
10 431.1 485.75 718.22 478.81 47.9 3850.59 6.88
20 383.2 485.75 718.22 478.81 95.8 3566.07 13.76
30 335.3 485.75 718.22 478.81 143.7 3281.54 20.64
40 287.4 485.75 718.22 478.81 191.6 2997.02 27.52
M 40 0 618 270.77 803.18 535.46 0 4987.78 0
10 556.2 270.77 803.18 535.46 61.8 4620.69 7.35
20 494.4 270.77 803.18 535.46 123.6 4253.59 14.71
30 432.6 270.77 803.18 535.46 185.4 3886.50 22.07
40 370.8 270.77 803.18 535.46 247.2 3519.41 29.43

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 K.V. Sabarish, R. Venkat Raman, R.Ancil, R. Wasim Raja, P. Selva Surendar

5. CONCLUSIONS
Based on limited experimental investigation concerning the compressive & split strength of
concrete, the following conclusions are drawn:
 Compressive strength reduces when cement replaced fly ash. As fly ash percentage increases
compressive strength and split strength decreases.
 Use of fly ash in concrete can save the coal & thermal industry disposal costs and produce a
„greener concrete for construction.
 The cost analysis indicates that percent cement reduction decreases cost of concrete, but at the
same time strength also decreases.
 This research concludes that fly ash can be innovative supplementary cementitious
Construction Material but judicious decisions are to be taken by engineers.

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