- Email: [email protected]
The strength and durability of fly ash and quarry dust light weight foam concrete
Materials Today: Proceedings xxx (xxxx) xxx
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
The strength and durability of fly ash and quarry dust light weight foam concrete R. Gopalakrishnan a,⇑, VM Sounthararajan b, A. Mohan a, M. Tholkapiyan c a
Department of Civil Engineering, SRM Easwari Engineering College, Chennai, TamilNadu, India Department of Civil Engineering, CMR Technical Campus, Hyderabad, Telangana, India c Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Department of Civil Engineering, Tandalam, Chennai 602105, India b
a r t i c l e
i n f o
Article history: Received 3 October 2019 Received in revised form 28 November 2019 Accepted 29 November 2019 Available online xxxx Keywords: Fly ash Durability Light weight foamed concrete Strength Quarry dust
a b s t r a c t This research work has been investigate on the foam concrete, which is an novel and very useful materials in construction industry , basically a cement mortar slurry with a maximum of 10% volume of foam. One of the main disadvantage of foam concrete is the large usage of river sand as a filler material, which leads to eco-friendly concrete. An experimental investigation has been done to effect of fly ash by partially replacing in cement from 0 to 50% and replacing river sand by quarry dust (0-50%) for various mixes. This research paper produce the compressive strength, split tensile strength and durability properties such as water absorption and permeability. From the investigation it have been concluded that the replacing partially 30% of fine sand b and quarry dust combination produced better quality results in par with the conventional foam concrete. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials Engineering and Characterization 2019.
1. Introduction Light weight concrete is low density a concrete and the values in par with the conventional concrete. Its density varies from 900- 1900 kg/m3 with reference to its compressive strength. It has good properties such as easy handling, preparing and cheaper, and hence this type of concrete popularizing in construction field. This light weight Foam concrete is produced by mixing the combination of conventional cement, fine aggregate, foaming agent with the compressed air [1]. In conjunction with the cement the pozzolanic materials such as Fly ash, Ground Granulated blast furnace slag are regularly used with the cement to enhance the durability and strength properties. Foam concrete needs low or no compaction or vibration and levelling as it is flowable. It is a thermal insulation material and best resistance to freeze and thaw and also shows high values in sound insulation. With the modern equipments manufacturing of foam concrete requires little to no compaction. The production of building blocks, floor screed, insulation for roofing, road sub- base materials can be produced
⇑ Corresponding author. E-mail address: [email protected] (R. Gopalakrishnan).
with a high quality with the new foaming agents and new equipments. In the year 2020, nearly 180,000 MW power will be produced annually, which may leads to produce around 190 MT of Coal Combustion Residue (CCR) per annum (expected by 2020) and of that the Bottom Ash generation may be increased to 40–50 MT per year [12]. The drawbacks with reference to foam concrete is the more consumption of river sand as filler material and setting of foam concrete. Utilization of industrial wastes as filler material in production of foam concrete will reduce the usage of river sand enormously, and there by depletion of sand is reduced by production of economic and environmental friendly material. The preparation of foam concrete has been aimed at to increase the setting process and thereby allowing for earlier removal formwork. Based on research work [13], it has been found that foaming agents produced with the basic materials of protein resulted in steady foam with more uniform and small sized air voids when compared to synthetic foaming agents which were further reviewed in [14]. Density and stability tests of foam were investigated by I [16], and [15] has done the investigation work on the production, Characteristics of aerated lightweight concrete and found that protein based agents were suitable for density ranges from 500 kg/m3 to 1700 kg/ m3 [17] Investigated on the influence of filler type on foam concrete and the study results indicated that
https://doi.org/10.1016/j.matpr.2019.11.317 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials Engineering and Characterization 2019.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
2
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
an increase in fly ash content improves the strength. The flowablity of pre-formed foam concrete mixtures depends on the filler type, i.e. consistency will be higher for mixes with fly ash as filler compared to mixes with sand as filler. An increase in fineness of sand or filler improved the strength, which was further proved by [18] and finally concluded that w/c ratio, compressive strength, flexural strength, and ductility were increased with fine sand. The behaviour of various porous aggregates has been done elaborately by various Researchers [19,20,21]. This research focuses the utilization of industrial wastes for production of foam concrete and also replacing fine aggregate by quarry dust.
2. Experimental\ 2.1. Cement A 53-grade type of ordinary Portland cement was used throughout the investigation of this research work and laboratory test value for specific gravity 3.15 as prescribed in IS 12269: 1987 [00].
2.2. Fly ash Class F type of low calcium fly ash is partially replaced in Portland cement to act as a binding particle and reduce the chloride permeability in concrete, therefore this type of alternate binding materials as more suitable in building construction industries. The various percentage of oxides present in the low calcium fly ash as reported in Table 1.
2.3. Filler materials
Fig. 1. Grading curve of fine aggregate, quarry dust and standard curve
Table 2 Properties of Foaming Agent.
Locally available river sand used for various mixes (0 to 100%) and test value for specific gravity of sand is 2.71, fineness modulus of 2.70 and confirming to Zone III as prescribed in IS 383[00]. Quarry stone dust was replaced in river sand from 0 to 50% for various mixes and having a specific gravity of 2.42, fineness modulus of 3.12 and confirming the Zone II as prescribed in IS 383-1987. The grading curve river sand vs Quarry and standard curve as shown in the Fig. 1.
2.4. Foaming Agent Foam agent prepared on the base of Protein was used for this investigation and its properties are given in Table 2. The foam was produced using foam generator by altering diluted foam agent at controlled pressures.
2.5. Water The normal water without any harmless was used and maintains the pH 7 and free from chloride content for various mixes.
Table 1 Observation test values for fly ash. Oxide Names
%
Silica Sio2 Aluminium Al2O3 Iron oxide Fe2O3 Calcium oxide (CaO) Magnesium oxide (MgO)
62.45 21.57 5.80 1.32 0.80
Descriptions of the properties
Results
Chemical Characterization Physical State pH
P-11 12.5 7
2.6. Production of Test Specimens Three various batches of the foamed concrete were considered in this study, as follows: Batch I, the conventional mix, including fine aggregate, cement, foaming agent and water; Batch II, which used the same ingredients except for the partial substitution of fly ash for cement; and Batch III, which used the combination of cement and fly ash as the binder content and river sand has been partially replaced by Quarry dust. A standard dosages level of superplasticiser at 0.5% by weight of binder content ,was added to the different batches to maintain the workability for various mixes are represented in Table 2. 2.7. Preparation of Specimens and Testing In total of three Batches of sixteen mixes details are given in Table 3. The specimen size of 100 mm x 100 mm x 100 mm were prepared and tested in compressive strength of light weight foam concrete at different curing days. For each batch triplicate sample has been prepared for testing. Besides that, sample of size 100 mm diameter and 200 mm height has been prepared for testing split tensile strength. Also, the samples were selected randomly has been prepared for testing water absorption and permeability test. The cubes and prisms specimens for testing were demoulded after 24 hours and air cured at room temperature. The compressive
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
3
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx Table 3 Mix designation and Mix proportions. Batch
Mix id
Target density (kg/m3)
Batch 1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16
1200 1200 1200 1200 1200 1200 1100 1100 1100 1100 1100 1150 1150 1150 1150 1150
Batch 2
Batch 3
Filler (%)
Binder (%)
Sand
Quarry dust
Cement
Fly ash
100 100 100 100 100 100 90 80 70 60 50 90 80 70 60 50
-
100 90 80 70 60 50 100 100 100 100 100 90 80 70 60 50
0 10 20 30 40 50 10 20 30 40 50
10 20 30 40 50 10 20 30 40 50
Water: Binder
Foam (%) by weight of binder
Sp (%)
Density obtained (kg/m3)
0.40
6
0.50
1172 1130 1120 1115 1110 1100 1145 1135 1125 1115 1100 1130 1120 1160 1170 1165
1180 1170
Density of foam concrete (kg/m3)
1160 1150 1140 1130 1120 1110 1100 1090 1080
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 Density 1172 1130 1120 1115 1110 1100 1145 1135 1125 1115 1100 1130 1140 1160 1170 1165
Compressive strength (MPa)
Fig. 2. Density of foamed concrete
11 10 9 8 7 6 5 4 3 2 1 0
0 Days
3 Days
7 days
14 days
28 days
F1
0
3.56
4.5
6.5
8.82
F2
0
3.46
4.25
5.5
7.5
F3
0
3.65
4.65
6.4
8.7
F4
0
3.7
4.8
6.7
10.2
F5
0
3.65
4.6
6.4
7.3
F6
0
3.55
4.4
5.8
6.7
Fig. 3. Compressive strength of Foam concrete(Cement and Fly ash blends)
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
4
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
strength and split tensile strength tests were conducted in accordance with BS 1881: Part 116: 1983 at 3 days, 7 days, 14 days and 28 days. Water absorption and permeability test were done according to the specification in the code ASTM C1585 and IS 3085-1965 respectively.
value of 1170 kg/m3, when compared to all the mixes. It was also observed that the all the values were nearer to the target density of 1100 to 1200 kg/m3 at 28 days. This finding showed that the combination of replacement of 30% Fly ash withquarry dust to cement and sand produced the better quality of light weight foam concrete.
3. Experimental test results and discussions
3.2. Compressive Strength of foam concrete
3.1. Density of Foamed Concrete
Fig. 3 shows that higher compressive strength of foam concrete was increased up to 15.64% at 28 days than to plain cement foam concrete. Further, increasing the content fly ash there was a drastic fall due to delay in setting properties of foam concrete during the pozzolanic reactions.
Compressive strength (MPa)
From the Fig. 2 explain that the results of foam concrete densities for various mixes. The experimental test results indicated that the density of foam concrete for the mix (F15) was achieved the highest
10 9 8 7 6 5 4 3 2 1 0 F1
0 Days 0
3 Days 3.56
7 days 4.5
14 days 6.5
28 days 8.82
F7
0
3.46
4.25
5.5
7.8
F8
0
3.25
4.05
5.1
6.7
F9
0
3.12
3.9
4.8
6
F10
0
3.08
3.75
5
5.45
F11
0
2.98
3.55
4.8
5.3
Compressive strength (MPa)
Fig. 4. Compressive strength of Foam concrete (Cement, partial replacement of sand by Quarry dust)
12 11 10 9 8 7 6 5 4 3 2 1 0 F1
0 days 0
3 Days 3.56
7 days 4.5
14 days 6.5
28 days 8.82
F12
0
3.42
4.25
5.4
7.1
F13
0
3.58
4.8
6.3
8.75
F14
0
4.2
5.5
8.5
11.25
F15
0
3.8
4.75
6.2
8.4
F16
0
3.2
4.25
5.1
6.5
Fig. 5. Compressive strength of Foam concrete (Cement, fly ash and partial replacement of sand by quarry dust)
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
5
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
Figs. 4 and 5 shows the comparison of compressive strength results of foamed concrete with various mixes with different percentages of PFA at various curing period. It is noted from the test results that the strength in compression for the control mix and different PFA mixes have continuous development of strength for different curing days. Generally, early compressive strengths of PFA foamed concretes (except 20% PFA, 1/3 b/s mix) was lower due to delay the pozzolanic reaction than compared to control mix. The Results indicated that the optimum PFA replacement for 1:2 binders/sand ratio mix is 30% and 20% for 1:3 binders/sand ratio mix for short term development of strength. 3.3. Split tensile strength of foam concrete
Split tensile strength (MPa)
The quality of foam agent is a very important liquid state is to produce the foaming and this type of agent is to be introduced into the Portland cement along with the different percentage of fly ash
1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0
and water mix thoroughly with few minutes followed by the compressed air pressure at constant level of 0.50 MPa to generate the foam after that this type of cellular paste to react as foam bubbles and bind the particles to make the stiffness of the concrete thus results to produce good strength of foam concrete. However, the desirable percentage of foaming agent is to be maintained with the pre-foaming of air is entrained into the cellular concrete before mixing. Fig. 6 shows split tensile strength of foam concrete was 1.67 MPa at 28 days in the case of plain cement concrete than compared to other types of mixes was slightly affected the strength of foam concrete. Fig. 7 shows the graphically represents the split tensile strength of foam concrete for various mixes from the experimental test results it is noted that there is no significant improvement in the combination of fly ash replaced in Portland cement due to the delay the setting properties at 28 days of curing compared to plain cement foam concrete.
1.67 1.2
F1
0 0 days 0
7 days 1.2
28 days 1.67
F2
0
1.05
1.42
F3
0
0.7
1.17
F4
0
0.5
0.92
F5
0
0.52
0.85
F6
0
0.5
0.8
Split tensile strength (MPa)
Fig. 6. Split Tensile strength of Foam concrete (Cement and Fly ash blends)
1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 F1
0 days 0
7 days 1.2
28 days 1.67
F7
0
1.05
1.35
F8
0
0.75
1.02
F9
0
0.45
0.87
F10
0
0.41
0.78
F11
0
0.39
0.7
Fig. 7. Split Tensile strength of Foam concrete (Cement, partial replacement of sand by Quarry dust)
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
6
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
Split tensile strength MPa
The experimental test result of 30% of fly ash with 30% of quarry dust shows that the higher split tensile strength is 1.75 MPa at 28 days with the w/b ratio of 0.4. Further, the addition content of fly ash in Portland cement there is a decreasing trend was noted in the case of F15-F16 mixes. Therefore, by considering an important parameter that’s the density of foam concrete is increased by corresponding split tensile strength also increasing as evidently shown in Fig. 8. Fig. 9 shows the foamed concrete for various mixes of test results from water absorption indicated that, less amount of water absorption is noted in the case of 30% of fly ash along with quarry dust at 28 days than compared to control concrete. The water absorption absorbed is directly related to the density of the foam concrete which results to increases the compressive strength of foam concrete (F-13 mix). This kind of relationship between the water absorption and strength density ratio of foam concrete was exponential because of particle size distribution with good packing density.
2 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0
The entire water absorption test results were plotted a Regression coefficient from the prediction of the coefficient R square value is equal to 0.9 therefore it is proved that the exact reliability of the proposed-model for various mixes. Based on the model is perfect accurate prediction because almost all the test dada is very close to the equality line thereby it is proved based on the water absorption concerning to increases the compressive strength of foam concrete for different mixes as shown in Fig. 10. Based on the various experimental test results, the higher strength of foam concrete at 28-days as of the best mix of F-1, F3, F-5, F-8, F-10, F-13 & F-14. After identification of best mix proportion was cast and tested to find out the permeability measurement at 28 days from the test results of lowest permeability of foam concrete is 9.56 m/sec (F-1 mix) the corresponding density value of 1019 kg/m3 and also observed in the case of F-13 mix is 9.70 m/sec at 28 days the corresponding density value of 1170 kg/m3. It clearly seems that the 30% of fly ash addition in Portland cement along with 30% of quarry dust replaced in river sand is
F1
0 days 0
7 days 1.2
28 days 1.67
F12
0
1.15
1.41
F13
0
0.9
1.28
F14
0
1.25
1.75
F15
0
0.97
1.3
F16
0
0.65
1.1
Fig. 8. Split Tensile strength of Foam concrete(Cement, fly ash and partial replacement of sand by Quarry dust)
18
Water absorption (%)
17 16 15 14 13 12 11 10 9 8 28 DAYS
F1 10.4
F3 11.5
F5 14.2
F8 14.5
F10 17.5
F13 9.8
F15 13.3
Fig. 9. Results of Water absorption test for various mixes.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
7
Water absorption (%)
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
W.A in %
Linear (W.A in %)
y = -1.955x + 28.14 R² = 0.9
6 6.25 6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9 9.25 9.5 9.75 10
Compressive strength (MPa)
Permeability (m /sec)
Fig. 10. Correlation of water absorption with compressive strength
18 17 16 15 14 13 12 11 10 9 8
28 DAYS
F1 9.56
F3 10.4
F5 13.5
F8 14.2
F10 17.3
F13 9.7
F15 13.5
Fig. 11. Water permeability of light weight foam concrete for various mixes.
working properly for various mixes of foamed concrete as shown in Fig. 11. 4. Conclusion From the various test results discussion and several conclusions of this research work was stated in order to achieve the main goal of the present investigations: The fly ash addition more than 30% in Portland cement emergence to produce the lower density of foam concrete decreases workability as well as affects the hardening properties. The expansion of the foamed concrete at the early ages is alarming the ability of the foamed concrete to continue hydration in the presence of moisture content. The optimum content of fly ash for foamed concrete to increase the higher short term compressive strength is achieved as 20% 25%.. Structural lightweight foam concrete compressive strength was 11.25 MPa the corresponding dry density value of 1170 kg/m3 at 28 days. The optimum mix showed higher values 27.55% for compressive strength, 4.79% for splitting tensile strength and less amount of water absorption up to 5.77% forat 28 days of water curingwhen compared to plain cement concrete mix.
Depends on experimental test results for various mixes, to obtain the optimum percentage of fly ash 30% along with 30% of quarry dust stone powder with 6% of foam is taken into consideration. Therefore, it is strongly recommended this type of cellular concrete based on the test results, wherever required for non-load bearing wall or partition wall this type of foam concrete is more suitable for building construction industries due to minimizing the self-weight of the member than compared to brick masonry wall which is consisting of 30% of fly ash replaced in Portland cement along with 30% quarry dust replaced in river sand.
Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. References [1] P. Risdanareni, M. Sulton, S.F. Nastiti, Light weight concrete for prefabricated house. In: Proceedings of the International Mechanical Engineering and Engineering Education Conferences (IMEEEC 2016), p. 030029- 1-6. [12] CEA, Central Electricity Authority Annual report, Government of India, 201415.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
8
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
[13] D.K. Panesar, Cellular concrete properties and the effect of synthetic and protein foaming agents, Constr. Build. Mater. 44 (2013) 575–584. [14] Y.H. Mugahed Amran, Nima Farzadnia, A.A. Abang Ali, Properties and applications of foamed concrete, a review, Constr. Build. Mater. 101 (2015) 990–1005. [15] A.J. Hamad, Materials, production, properties and application of aerated lightweight concrete, Int. J. Mater. Sci. Eng. 2 (2014) 152–157. [16] Indu Siva Ranjani, K. Ramamurthy, Relative assessment of density and stability of foam Produced with four synthetic surfactants, Mater. Struct. 43 (2010) 1317–1325. [17] E.K. Kunhanandan Nambiar, K. Ramamurthy, Influence of filler type on the properties of foam concrete, Cem. Concr. Compos. 28 (2006) 475–480. [18] S.K. Lim, C.S. Tan, X. Zhao, T.C. Ling, Strength and toughness of lightweight foamed concrete with different sand grading, KSCE J. Civ. Eng. 19 (2015) 2191–2197. [19] D. Bentz, K. Snyder, Protected paste volume in concrete: extension to internal curing using saturated lightweight fine aggregate, Cem. Concr. 29 (1999) 1863–1867. [20] S. Zhutovsky, K. Kovler, A. Bentur, Influence of cement paste matrix properties on the autogenous curing of high-performance concrete, Cem. Concr. Compos. 26 (2004) 499–507. [21] J. Schlitter, R. Henkensiefken, J. Castro, K. Raoufi, J. Weiss, T. Nantung, Development of Internally Cured Concrete for Increased Service Life, 2010.
[3] E. Namsone, G. Sahmenko, A. Korjakins, Reduction of the capillary water absorption of foamed concrete by using the porous aggregate, Mater. Sci. Eng. 9 (2017) 1–9. [4] K. Brady, G. Watts, M.R. Jones, Specification for Foamed Concrete. Highways Agency and TRL Application Guide AG 39, 2001. [5] E.P. Kearsley, M. Visagie, Micro-properties of foamed concrete. In: R.K. Dhir, N. A. Henderson (Eds.), Specialist Techniques and Materials for Concrete Construction. Thomas Telford, UK, 1999. [6] R.C. Valore, Cellular concrete part 1 composition and methods of production, ACI J. 50 (1954) 773–796. [7] S. Mindess, Developments in the Formulation and Reinforcement of Concrete, Woodhead Pub., Cambridge, England, 2008. [8] M.H. HanizamAwang, Durability properties of foamed concrete with fiber inclusion, World Acad. Sci. Eng. Technol. Int. J. civil Vol (2014) 8. [9] M. Jones, A. McCarthy, Preliminary views on the potential of foamed concrete as a structural material, Mag. Concr. Res. 57 (1) (2005) 21–31. [10] P.A. Patel, A.K. Desai, J.A. Desai, Evaluation of engineering properties for polypropylene fiber reinforced concrete, Int. J. Adv. Eng. Technol. 3 (1) (2012) 42–45. [11] A. Sadrmomtazi, A. Fasihi, A. Haghi, Effect of polypropylene fiber on mechanical and physical properties of mortars containing NANO-SIO2. in: Proceedings of the Third International Conference on Concrete and Development pp. 1163–1172, 2008.
Further reading [2] G. Krishnan, K.B. Anand, Industrial waste utilization for foam concrete, Mater. Sci. Eng. 4 (2016) 4–10.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
The strength and durability of fly ash and quarry dust light weight foam concrete R. Gopalakrishnan a,⇑, VM Sounthararajan b, A. Mohan a, M. Tholkapiyan c a
Department of Civil Engineering, SRM Easwari Engineering College, Chennai, TamilNadu, India Department of Civil Engineering, CMR Technical Campus, Hyderabad, Telangana, India c Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Department of Civil Engineering, Tandalam, Chennai 602105, India b
a r t i c l e
i n f o
Article history: Received 3 October 2019 Received in revised form 28 November 2019 Accepted 29 November 2019 Available online xxxx Keywords: Fly ash Durability Light weight foamed concrete Strength Quarry dust
a b s t r a c t This research work has been investigate on the foam concrete, which is an novel and very useful materials in construction industry , basically a cement mortar slurry with a maximum of 10% volume of foam. One of the main disadvantage of foam concrete is the large usage of river sand as a filler material, which leads to eco-friendly concrete. An experimental investigation has been done to effect of fly ash by partially replacing in cement from 0 to 50% and replacing river sand by quarry dust (0-50%) for various mixes. This research paper produce the compressive strength, split tensile strength and durability properties such as water absorption and permeability. From the investigation it have been concluded that the replacing partially 30% of fine sand b and quarry dust combination produced better quality results in par with the conventional foam concrete. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials Engineering and Characterization 2019.
1. Introduction Light weight concrete is low density a concrete and the values in par with the conventional concrete. Its density varies from 900- 1900 kg/m3 with reference to its compressive strength. It has good properties such as easy handling, preparing and cheaper, and hence this type of concrete popularizing in construction field. This light weight Foam concrete is produced by mixing the combination of conventional cement, fine aggregate, foaming agent with the compressed air [1]. In conjunction with the cement the pozzolanic materials such as Fly ash, Ground Granulated blast furnace slag are regularly used with the cement to enhance the durability and strength properties. Foam concrete needs low or no compaction or vibration and levelling as it is flowable. It is a thermal insulation material and best resistance to freeze and thaw and also shows high values in sound insulation. With the modern equipments manufacturing of foam concrete requires little to no compaction. The production of building blocks, floor screed, insulation for roofing, road sub- base materials can be produced
⇑ Corresponding author. E-mail address: [email protected] (R. Gopalakrishnan).
with a high quality with the new foaming agents and new equipments. In the year 2020, nearly 180,000 MW power will be produced annually, which may leads to produce around 190 MT of Coal Combustion Residue (CCR) per annum (expected by 2020) and of that the Bottom Ash generation may be increased to 40–50 MT per year [12]. The drawbacks with reference to foam concrete is the more consumption of river sand as filler material and setting of foam concrete. Utilization of industrial wastes as filler material in production of foam concrete will reduce the usage of river sand enormously, and there by depletion of sand is reduced by production of economic and environmental friendly material. The preparation of foam concrete has been aimed at to increase the setting process and thereby allowing for earlier removal formwork. Based on research work [13], it has been found that foaming agents produced with the basic materials of protein resulted in steady foam with more uniform and small sized air voids when compared to synthetic foaming agents which were further reviewed in [14]. Density and stability tests of foam were investigated by I [16], and [15] has done the investigation work on the production, Characteristics of aerated lightweight concrete and found that protein based agents were suitable for density ranges from 500 kg/m3 to 1700 kg/ m3 [17] Investigated on the influence of filler type on foam concrete and the study results indicated that
https://doi.org/10.1016/j.matpr.2019.11.317 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials Engineering and Characterization 2019.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
2
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
an increase in fly ash content improves the strength. The flowablity of pre-formed foam concrete mixtures depends on the filler type, i.e. consistency will be higher for mixes with fly ash as filler compared to mixes with sand as filler. An increase in fineness of sand or filler improved the strength, which was further proved by [18] and finally concluded that w/c ratio, compressive strength, flexural strength, and ductility were increased with fine sand. The behaviour of various porous aggregates has been done elaborately by various Researchers [19,20,21]. This research focuses the utilization of industrial wastes for production of foam concrete and also replacing fine aggregate by quarry dust.
2. Experimental\ 2.1. Cement A 53-grade type of ordinary Portland cement was used throughout the investigation of this research work and laboratory test value for specific gravity 3.15 as prescribed in IS 12269: 1987 [00].
2.2. Fly ash Class F type of low calcium fly ash is partially replaced in Portland cement to act as a binding particle and reduce the chloride permeability in concrete, therefore this type of alternate binding materials as more suitable in building construction industries. The various percentage of oxides present in the low calcium fly ash as reported in Table 1.
2.3. Filler materials
Fig. 1. Grading curve of fine aggregate, quarry dust and standard curve
Table 2 Properties of Foaming Agent.
Locally available river sand used for various mixes (0 to 100%) and test value for specific gravity of sand is 2.71, fineness modulus of 2.70 and confirming to Zone III as prescribed in IS 383[00]. Quarry stone dust was replaced in river sand from 0 to 50% for various mixes and having a specific gravity of 2.42, fineness modulus of 3.12 and confirming the Zone II as prescribed in IS 383-1987. The grading curve river sand vs Quarry and standard curve as shown in the Fig. 1.
2.4. Foaming Agent Foam agent prepared on the base of Protein was used for this investigation and its properties are given in Table 2. The foam was produced using foam generator by altering diluted foam agent at controlled pressures.
2.5. Water The normal water without any harmless was used and maintains the pH 7 and free from chloride content for various mixes.
Table 1 Observation test values for fly ash. Oxide Names
%
Silica Sio2 Aluminium Al2O3 Iron oxide Fe2O3 Calcium oxide (CaO) Magnesium oxide (MgO)
62.45 21.57 5.80 1.32 0.80
Descriptions of the properties
Results
Chemical Characterization Physical State pH
P-11 12.5 7
2.6. Production of Test Specimens Three various batches of the foamed concrete were considered in this study, as follows: Batch I, the conventional mix, including fine aggregate, cement, foaming agent and water; Batch II, which used the same ingredients except for the partial substitution of fly ash for cement; and Batch III, which used the combination of cement and fly ash as the binder content and river sand has been partially replaced by Quarry dust. A standard dosages level of superplasticiser at 0.5% by weight of binder content ,was added to the different batches to maintain the workability for various mixes are represented in Table 2. 2.7. Preparation of Specimens and Testing In total of three Batches of sixteen mixes details are given in Table 3. The specimen size of 100 mm x 100 mm x 100 mm were prepared and tested in compressive strength of light weight foam concrete at different curing days. For each batch triplicate sample has been prepared for testing. Besides that, sample of size 100 mm diameter and 200 mm height has been prepared for testing split tensile strength. Also, the samples were selected randomly has been prepared for testing water absorption and permeability test. The cubes and prisms specimens for testing were demoulded after 24 hours and air cured at room temperature. The compressive
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
3
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx Table 3 Mix designation and Mix proportions. Batch
Mix id
Target density (kg/m3)
Batch 1
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16
1200 1200 1200 1200 1200 1200 1100 1100 1100 1100 1100 1150 1150 1150 1150 1150
Batch 2
Batch 3
Filler (%)
Binder (%)
Sand
Quarry dust
Cement
Fly ash
100 100 100 100 100 100 90 80 70 60 50 90 80 70 60 50
-
100 90 80 70 60 50 100 100 100 100 100 90 80 70 60 50
0 10 20 30 40 50 10 20 30 40 50
10 20 30 40 50 10 20 30 40 50
Water: Binder
Foam (%) by weight of binder
Sp (%)
Density obtained (kg/m3)
0.40
6
0.50
1172 1130 1120 1115 1110 1100 1145 1135 1125 1115 1100 1130 1120 1160 1170 1165
1180 1170
Density of foam concrete (kg/m3)
1160 1150 1140 1130 1120 1110 1100 1090 1080
F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 Density 1172 1130 1120 1115 1110 1100 1145 1135 1125 1115 1100 1130 1140 1160 1170 1165
Compressive strength (MPa)
Fig. 2. Density of foamed concrete
11 10 9 8 7 6 5 4 3 2 1 0
0 Days
3 Days
7 days
14 days
28 days
F1
0
3.56
4.5
6.5
8.82
F2
0
3.46
4.25
5.5
7.5
F3
0
3.65
4.65
6.4
8.7
F4
0
3.7
4.8
6.7
10.2
F5
0
3.65
4.6
6.4
7.3
F6
0
3.55
4.4
5.8
6.7
Fig. 3. Compressive strength of Foam concrete(Cement and Fly ash blends)
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
4
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
strength and split tensile strength tests were conducted in accordance with BS 1881: Part 116: 1983 at 3 days, 7 days, 14 days and 28 days. Water absorption and permeability test were done according to the specification in the code ASTM C1585 and IS 3085-1965 respectively.
value of 1170 kg/m3, when compared to all the mixes. It was also observed that the all the values were nearer to the target density of 1100 to 1200 kg/m3 at 28 days. This finding showed that the combination of replacement of 30% Fly ash withquarry dust to cement and sand produced the better quality of light weight foam concrete.
3. Experimental test results and discussions
3.2. Compressive Strength of foam concrete
3.1. Density of Foamed Concrete
Fig. 3 shows that higher compressive strength of foam concrete was increased up to 15.64% at 28 days than to plain cement foam concrete. Further, increasing the content fly ash there was a drastic fall due to delay in setting properties of foam concrete during the pozzolanic reactions.
Compressive strength (MPa)
From the Fig. 2 explain that the results of foam concrete densities for various mixes. The experimental test results indicated that the density of foam concrete for the mix (F15) was achieved the highest
10 9 8 7 6 5 4 3 2 1 0 F1
0 Days 0
3 Days 3.56
7 days 4.5
14 days 6.5
28 days 8.82
F7
0
3.46
4.25
5.5
7.8
F8
0
3.25
4.05
5.1
6.7
F9
0
3.12
3.9
4.8
6
F10
0
3.08
3.75
5
5.45
F11
0
2.98
3.55
4.8
5.3
Compressive strength (MPa)
Fig. 4. Compressive strength of Foam concrete (Cement, partial replacement of sand by Quarry dust)
12 11 10 9 8 7 6 5 4 3 2 1 0 F1
0 days 0
3 Days 3.56
7 days 4.5
14 days 6.5
28 days 8.82
F12
0
3.42
4.25
5.4
7.1
F13
0
3.58
4.8
6.3
8.75
F14
0
4.2
5.5
8.5
11.25
F15
0
3.8
4.75
6.2
8.4
F16
0
3.2
4.25
5.1
6.5
Fig. 5. Compressive strength of Foam concrete (Cement, fly ash and partial replacement of sand by quarry dust)
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
5
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
Figs. 4 and 5 shows the comparison of compressive strength results of foamed concrete with various mixes with different percentages of PFA at various curing period. It is noted from the test results that the strength in compression for the control mix and different PFA mixes have continuous development of strength for different curing days. Generally, early compressive strengths of PFA foamed concretes (except 20% PFA, 1/3 b/s mix) was lower due to delay the pozzolanic reaction than compared to control mix. The Results indicated that the optimum PFA replacement for 1:2 binders/sand ratio mix is 30% and 20% for 1:3 binders/sand ratio mix for short term development of strength. 3.3. Split tensile strength of foam concrete
Split tensile strength (MPa)
The quality of foam agent is a very important liquid state is to produce the foaming and this type of agent is to be introduced into the Portland cement along with the different percentage of fly ash
1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0
and water mix thoroughly with few minutes followed by the compressed air pressure at constant level of 0.50 MPa to generate the foam after that this type of cellular paste to react as foam bubbles and bind the particles to make the stiffness of the concrete thus results to produce good strength of foam concrete. However, the desirable percentage of foaming agent is to be maintained with the pre-foaming of air is entrained into the cellular concrete before mixing. Fig. 6 shows split tensile strength of foam concrete was 1.67 MPa at 28 days in the case of plain cement concrete than compared to other types of mixes was slightly affected the strength of foam concrete. Fig. 7 shows the graphically represents the split tensile strength of foam concrete for various mixes from the experimental test results it is noted that there is no significant improvement in the combination of fly ash replaced in Portland cement due to the delay the setting properties at 28 days of curing compared to plain cement foam concrete.
1.67 1.2
F1
0 0 days 0
7 days 1.2
28 days 1.67
F2
0
1.05
1.42
F3
0
0.7
1.17
F4
0
0.5
0.92
F5
0
0.52
0.85
F6
0
0.5
0.8
Split tensile strength (MPa)
Fig. 6. Split Tensile strength of Foam concrete (Cement and Fly ash blends)
1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 F1
0 days 0
7 days 1.2
28 days 1.67
F7
0
1.05
1.35
F8
0
0.75
1.02
F9
0
0.45
0.87
F10
0
0.41
0.78
F11
0
0.39
0.7
Fig. 7. Split Tensile strength of Foam concrete (Cement, partial replacement of sand by Quarry dust)
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
6
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
Split tensile strength MPa
The experimental test result of 30% of fly ash with 30% of quarry dust shows that the higher split tensile strength is 1.75 MPa at 28 days with the w/b ratio of 0.4. Further, the addition content of fly ash in Portland cement there is a decreasing trend was noted in the case of F15-F16 mixes. Therefore, by considering an important parameter that’s the density of foam concrete is increased by corresponding split tensile strength also increasing as evidently shown in Fig. 8. Fig. 9 shows the foamed concrete for various mixes of test results from water absorption indicated that, less amount of water absorption is noted in the case of 30% of fly ash along with quarry dust at 28 days than compared to control concrete. The water absorption absorbed is directly related to the density of the foam concrete which results to increases the compressive strength of foam concrete (F-13 mix). This kind of relationship between the water absorption and strength density ratio of foam concrete was exponential because of particle size distribution with good packing density.
2 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0
The entire water absorption test results were plotted a Regression coefficient from the prediction of the coefficient R square value is equal to 0.9 therefore it is proved that the exact reliability of the proposed-model for various mixes. Based on the model is perfect accurate prediction because almost all the test dada is very close to the equality line thereby it is proved based on the water absorption concerning to increases the compressive strength of foam concrete for different mixes as shown in Fig. 10. Based on the various experimental test results, the higher strength of foam concrete at 28-days as of the best mix of F-1, F3, F-5, F-8, F-10, F-13 & F-14. After identification of best mix proportion was cast and tested to find out the permeability measurement at 28 days from the test results of lowest permeability of foam concrete is 9.56 m/sec (F-1 mix) the corresponding density value of 1019 kg/m3 and also observed in the case of F-13 mix is 9.70 m/sec at 28 days the corresponding density value of 1170 kg/m3. It clearly seems that the 30% of fly ash addition in Portland cement along with 30% of quarry dust replaced in river sand is
F1
0 days 0
7 days 1.2
28 days 1.67
F12
0
1.15
1.41
F13
0
0.9
1.28
F14
0
1.25
1.75
F15
0
0.97
1.3
F16
0
0.65
1.1
Fig. 8. Split Tensile strength of Foam concrete(Cement, fly ash and partial replacement of sand by Quarry dust)
18
Water absorption (%)
17 16 15 14 13 12 11 10 9 8 28 DAYS
F1 10.4
F3 11.5
F5 14.2
F8 14.5
F10 17.5
F13 9.8
F15 13.3
Fig. 9. Results of Water absorption test for various mixes.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
7
Water absorption (%)
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
W.A in %
Linear (W.A in %)
y = -1.955x + 28.14 R² = 0.9
6 6.25 6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9 9.25 9.5 9.75 10
Compressive strength (MPa)
Permeability (m /sec)
Fig. 10. Correlation of water absorption with compressive strength
18 17 16 15 14 13 12 11 10 9 8
28 DAYS
F1 9.56
F3 10.4
F5 13.5
F8 14.2
F10 17.3
F13 9.7
F15 13.5
Fig. 11. Water permeability of light weight foam concrete for various mixes.
working properly for various mixes of foamed concrete as shown in Fig. 11. 4. Conclusion From the various test results discussion and several conclusions of this research work was stated in order to achieve the main goal of the present investigations: The fly ash addition more than 30% in Portland cement emergence to produce the lower density of foam concrete decreases workability as well as affects the hardening properties. The expansion of the foamed concrete at the early ages is alarming the ability of the foamed concrete to continue hydration in the presence of moisture content. The optimum content of fly ash for foamed concrete to increase the higher short term compressive strength is achieved as 20% 25%.. Structural lightweight foam concrete compressive strength was 11.25 MPa the corresponding dry density value of 1170 kg/m3 at 28 days. The optimum mix showed higher values 27.55% for compressive strength, 4.79% for splitting tensile strength and less amount of water absorption up to 5.77% forat 28 days of water curingwhen compared to plain cement concrete mix.
Depends on experimental test results for various mixes, to obtain the optimum percentage of fly ash 30% along with 30% of quarry dust stone powder with 6% of foam is taken into consideration. Therefore, it is strongly recommended this type of cellular concrete based on the test results, wherever required for non-load bearing wall or partition wall this type of foam concrete is more suitable for building construction industries due to minimizing the self-weight of the member than compared to brick masonry wall which is consisting of 30% of fly ash replaced in Portland cement along with 30% quarry dust replaced in river sand.
Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper. References [1] P. Risdanareni, M. Sulton, S.F. Nastiti, Light weight concrete for prefabricated house. In: Proceedings of the International Mechanical Engineering and Engineering Education Conferences (IMEEEC 2016), p. 030029- 1-6. [12] CEA, Central Electricity Authority Annual report, Government of India, 201415.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317
8
R. Gopalakrishnan et al. / Materials Today: Proceedings xxx (xxxx) xxx
[13] D.K. Panesar, Cellular concrete properties and the effect of synthetic and protein foaming agents, Constr. Build. Mater. 44 (2013) 575–584. [14] Y.H. Mugahed Amran, Nima Farzadnia, A.A. Abang Ali, Properties and applications of foamed concrete, a review, Constr. Build. Mater. 101 (2015) 990–1005. [15] A.J. Hamad, Materials, production, properties and application of aerated lightweight concrete, Int. J. Mater. Sci. Eng. 2 (2014) 152–157. [16] Indu Siva Ranjani, K. Ramamurthy, Relative assessment of density and stability of foam Produced with four synthetic surfactants, Mater. Struct. 43 (2010) 1317–1325. [17] E.K. Kunhanandan Nambiar, K. Ramamurthy, Influence of filler type on the properties of foam concrete, Cem. Concr. Compos. 28 (2006) 475–480. [18] S.K. Lim, C.S. Tan, X. Zhao, T.C. Ling, Strength and toughness of lightweight foamed concrete with different sand grading, KSCE J. Civ. Eng. 19 (2015) 2191–2197. [19] D. Bentz, K. Snyder, Protected paste volume in concrete: extension to internal curing using saturated lightweight fine aggregate, Cem. Concr. 29 (1999) 1863–1867. [20] S. Zhutovsky, K. Kovler, A. Bentur, Influence of cement paste matrix properties on the autogenous curing of high-performance concrete, Cem. Concr. Compos. 26 (2004) 499–507. [21] J. Schlitter, R. Henkensiefken, J. Castro, K. Raoufi, J. Weiss, T. Nantung, Development of Internally Cured Concrete for Increased Service Life, 2010.
[3] E. Namsone, G. Sahmenko, A. Korjakins, Reduction of the capillary water absorption of foamed concrete by using the porous aggregate, Mater. Sci. Eng. 9 (2017) 1–9. [4] K. Brady, G. Watts, M.R. Jones, Specification for Foamed Concrete. Highways Agency and TRL Application Guide AG 39, 2001. [5] E.P. Kearsley, M. Visagie, Micro-properties of foamed concrete. In: R.K. Dhir, N. A. Henderson (Eds.), Specialist Techniques and Materials for Concrete Construction. Thomas Telford, UK, 1999. [6] R.C. Valore, Cellular concrete part 1 composition and methods of production, ACI J. 50 (1954) 773–796. [7] S. Mindess, Developments in the Formulation and Reinforcement of Concrete, Woodhead Pub., Cambridge, England, 2008. [8] M.H. HanizamAwang, Durability properties of foamed concrete with fiber inclusion, World Acad. Sci. Eng. Technol. Int. J. civil Vol (2014) 8. [9] M. Jones, A. McCarthy, Preliminary views on the potential of foamed concrete as a structural material, Mag. Concr. Res. 57 (1) (2005) 21–31. [10] P.A. Patel, A.K. Desai, J.A. Desai, Evaluation of engineering properties for polypropylene fiber reinforced concrete, Int. J. Adv. Eng. Technol. 3 (1) (2012) 42–45. [11] A. Sadrmomtazi, A. Fasihi, A. Haghi, Effect of polypropylene fiber on mechanical and physical properties of mortars containing NANO-SIO2. in: Proceedings of the Third International Conference on Concrete and Development pp. 1163–1172, 2008.
Further reading [2] G. Krishnan, K.B. Anand, Industrial waste utilization for foam concrete, Mater. Sci. Eng. 4 (2016) 4–10.
Please cite this article as: R. Gopalakrishnan, V. Sounthararajan, A. Mohan et al., The strength and durability of fly ash and quarry dust light weight foam concrete, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.317