CHAPTER NO 1

INTRODUCTION
1.1 General
In the recent years, there is great development in the area of admixtures and now a
day, the pozzolanic admixtures like fly ash, micro silica are commonly used to
enhance performance characteristics of concrete. It is need of time to design and
construct the structures which will have greater durability and strength and which have
led to develop concept of high performance concrete. The major intension in
developing high performance concrete is to have adequate resistance to aggressive
environments and to make the structure impermeable. However, use of pozzolanic
admixtures like micro silica adds to the cost of concrete which directly affects the cost
of the project. It is need to find out the substitute to micro silica without sacrificing the
quality and performance of High performance concrete. One of the better alternatives
to Micro silica is GGBS. Civil structures made of steel reinforced concrete normally
suffer from corrosion of the steel by the salt, which results in the failure of those
structures. Constant maintenance and repairing is needed to enhance the life cycle of
those civil structures. There are many ways to minimize the failure of the concrete
structures made of steel reinforce concrete. The custom approach is to adhesively bond
fibre polymer composites onto the structure. This also helps to increase the toughness
and tensile strength and improve the cracking and deformation characteristics of the
resultant composite. But this method adds another layer, which is prone to
degradation. These fibre polymer composites have been shown to suffer from
degradation when exposed to marine environment due to surface blistering. As a
result, the adhesive bond strength is reduced, which results in the de-lamination of the
composite. The principal reason for incorporating fibres into a cement matrix is to
increase the toughness and tensile strength, and improve the cracking deformation
characteristics of the resultant composite. In order for fibre reinforced concrete (FRC)
to be a viable construction material, it must be able to compete economically with
existing reinforcing systems. As GGBS is good in resisting salt corrosion & chemical
reactions it enhances the properties of FRC.
Ground granulated blast furnace slag or slag is the by-product of smelting ore to
purify metals. They can be considered to be a mixture of metal oxides. However, they
can contain metal sulphide sand metal atoms in the elemental form. Slag is generally
1
used as a waste removal mechanism in metal smelting but they can also serve other
purposes such as assisting in smelt temperature control and to minimize re-oxidation
of the final product before casting. Slag has a pozzolanic reaction which allows the
increase of concrete strength. Slag has proven to produce very good and dense
concrete allowing increased durability. It is observed from the studies, concrete made
with GGBS continues to gain strength over time, and has been shown to double its 28-
day strength over periods of 10 to 12 years.

2
1.2 Scope of Work
Use of GGBFS as a partial replacement of cement in concrete is a new option that
has now emerged in the world of concrete. As GGBFS is a waste material produced
from the steel industry. It has got one of its application, which is studied in this
seminar report and the same enhances waste management. This replacement reduces
the demand of deficient cement and ultimately solves some environmental concerns.
Scope of present work is to use the optimum ratio of the materials which will
enhance the different parameters of the concrete.
1.3 Objectives
The main objectives of this study are:-
 To determine the performance of concrete by partial replacement of
cement by GGBFS in 0%,10%, 20%, 30% & 40 % variants.
 To determine the performance of concrete by partial replacement of
cement by GGBFS and steel and polypropylene fibre 0.5%, 1%, 1.5%, 2% by
volume of concrete.
 To determine the compressive strength and split tensile strength of
concrete for 7 days and 28 days curing.
 To determine the most appropriate percentage of GGFBS in concrete which
gives high strength and result.

1.4 Problem Statement

GGBFS is easily available by product of iron. Current total production of steel slag in
India is around 12 million tons per annum. It gives strength to concrete and enhance its
properties. To reduce cost of construction it is used. Hence we have to replace cement
by cheap and economical material like ground granulated blast furnace slag.

1.5 Advantages and Disadvantages of GGBFS in concrete

1.5.1 Advantages
 GGBFS improves workability, pump ability and compaction characteristics for
concrete placement.
 GBBS in concrete reduces the heat of hydration in concrete.
 GGBFS in concrete also increases the fire resistance property of concrete.

3
  GGBFS in concrete provides protection against both sulphates attack and
chloride attack.
 GGBFS also used for architectural work.
 Concrete containing GGBFS cement has a higher ultimate strength than
concrete made with Portland cement.
 GGBFS in concrete extends the life cycle of concrete structure.
 It also reduces the maintenance cost of the structure.

1.5.2 Disadvantages
 The aspect that most concerns people is the lower early age strength. Because
concrete made with GGBFS goes through a 2-stage hydration process the
initial reaction is slow.
 Concrete with a high percentage of GGBFS used in a thin element in cold
weather will have a lower strength and may require formwork to be in place
longer.
 Again at higher percentages the initial carbonation rate may be a little higher,
although this tends not be an issue as for standard cover the depth of
carbonation typically doesn't impact on the reinforcing.

4
 CHAPTER NO 2
LITERATURE REVIEW
2.1 General
As per the discussion in previous chapter, GGBFS is a waste product from iron
manufacturing industry. And Copper slag is produced during pyro metallurgical
production of copper from copper ores. So as to achieve sustainable development with
fewer hazards to our environment, use of GGBFS as a partial replacement for cement
and Copper slag as a partial replacement for fine aggregate is a wise solution. As this
leads to economical use of cement, whose production badly affects the environment?
So some of the authors have recently carried out their research based on use of
GGBFS and copper slag and published their research work in renowned journals.
The Ground Granulated Blast Furnace Slag is a by-product of iron
manufacturing industry. Iron ore, coke and limestone are fed into the furnace and
molten slag floats above the molten iron at a temperature of about 15000C to 16000C
as a resultant. The composition of molten slag about 30% to 40% SiO2 and about 40%
CaO, which is almost equal to the chemical composition of Portland cement. The
molten slag, is water-quenched rapidly, after the molten iron is trapped off which
results in the formation of a glassy granulate. The molten slag consists of mainly
siliceous and aluminous residue. This glassy granulate is dried and ground to the
required size, which is known as Ground Granulated Blast Furnace Slag (GGBFS).
The production of GGBFS requires more energy as compared with the energy needed
for the production of Portland cement. By replacing the Portland cement with GGBFS
will results in reduction of carbon dioxide gas emission. It is therefore an
environmentally friendly construction material. GGBFS from modern thermal power
plants generally does not require processing prior to being incorporated into concrete
and is therefore considered to be an environmentally free input material. We can
replace about 80% of the Portland cement by using GGBFS in concrete. GGBFS has
characteristics of better water impermeability as well as improved resistance to
corrosion and sulphate attack. Due to lower heat hydration it reduces the risk of
thermal cracking. It has higher durability, workability, reduces permeability to external
agencies, which helps in making, placing and compaction easier. As a result, the
service life of a structure is enhanced and the maintenance cost reduced.

5
1] Siddharth (2005)- In this experimental work the compressive strength, split
tensile strength, flexural strength tests were conducted by adding ground granulated
blast furnace slag (GGBFS) in various percentage of 0%, 10%, 20%, 30% and 40% to
the weight of cement and 1% steel fibres of round crimped type having aspect ratio 54
were used. From the test results it was concluded that strength of the concrete
increases with the increase of GGBFS up to 40% and also increase in load carrying
capacity of40% GGBFS beams compare to conventional beams. From the overall
study it was concluded that there was improvement in the strength of concrete by
addition of GGBFS up to 40% with 1% of steel fibre(SF).

2] Danying Gao (2012)-carried out to investigate the splitting properties of fibre

Reinforced ground granulated blast furnace slag (GGBFS) concrete after exposure to
elevated temperatures. Based on experimental observation, the effect of GGBFS
content, steel fibre dosage, polypropylene (PP) fibre dosage and strength grade
of concrete on the residual splitting strength of the concrete after being subjected to
high temperature was systematically analysed. Test data indicated that high
temperature caused significant deterioration in the splitting strength of concrete;
the addition of GGBFS, PP fibre and steel fibre could all effectively improve
the residual splitting properties of concrete; the optimum amount of GGBFS, PP fibre
and steel fibre were identified, respectively; the degree of strength loss of concrete
with different strength grades was very close to each other. A set of theoretical
equations was proposed to predict the residual splitting strength of concrete after being
heated to temperatures up to 800°C.

3] S. P. Sangeetha (2014)-Author carried out the study on flexural behaviour of

reinforced concrete beams with partial replacement of GGBFS. And this study focuses
on the structural behaviour of reinforced concrete beam with Ground Granulated Blast
Furnace Slag (GGBFS).It is an inexpensive replacement of Ordinary Portland Cement
(OPC) used in concrete, and it improved fresh and hardened properties of concrete.
Experimental investigation included testing of eight reinforced concrete beams with
and without GGBFS. Portland cement was replaced with 40% GGBFS and Gallium B-
233 was used as super plasticizer for the casting of beams. The results of laboratory
investigation on the structural behaviour of reinforced concrete beams with GGBFS

6
are presented. Data presented include the load-deflection characteristics,
cracking behaviour, strain characteristics and moment- curvature of the reinforced
concrete beams with and without GGBFS when tested at 28 days and 56 days. The
investigation revealed that the flexural behaviour of reinforced GGBFS concrete
beams is comparable to that of reinforced concrete beams.

4] Premlal (2015)-In this research, they studied on the strength and durability
characteristics of steel fibre reinforced concrete containing copper slag as partial
replacement of fine aggregate. Mix proportion for M20 normal concrete was decided
and Sand was replaced with copper slag in proportions of 0%, 10%, 20%, 30%, 40%,
50% & 60%. In all mixes, the proportion of steel fibre were kept constant i.e., 0.2% by
volume of concrete. All hybrid mixes were tested and then it was found that Steel fibre
reinforced concrete containing copper slag as 40 % partial replacement of fine
aggregate gives maximum strength and durability criteria.

5] M. PavanKumar (2015)- In this study, they had also studied the mechanical
behaviour of M25 concrete mix by partial replacing with advanced mineral admixtures
Such as Copper slag and GGBFS in concrete mix. In this study, partial replacement of
Cement with GGBFS and Sand with Copper Slag was done. And experimental study
was conducted to evaluate the workability and strength characteristics of hardened
concrete, properties of concrete has been assessed by partially replacing cement with
GGBFS, and sand with Copper Slag. The cement has been replaced by GGBFS
accordingly in the range of 0% (without GGBFS), 5%, 10%, 15%, and 20% by weight
of cement for M25 mix. The sand has been replaced by Copper slag accordingly
in the range of 0% (without Copper slag), 10%, 20%, 30%, and 40% by weight of
cement for M25 mix. Concrete mixtures were produced, tested and compared in
terms of compressive, flexural and split tensile strength with the conventional
concrete. The compressive strength for partial replacement of fine aggregate with
copper slag increased up to 30% replacement and later on decreased by 11% for 50%
replacement. Similarly, for other tests such as split tensile strength, flexural strength
the values increased up to 30% replacement for copper slag and 15% GGBFS with
the weight of the cement. So optimum replacement for copper slag and GGBFS was
found to be 30% for copper slag and 15% for GGBFS.

7
6] Santosh Kumar Karri (2015) - In the research paper naming Strength and
Durability Studies on GGBFS Concrete shows that, Workability of concrete increases
with the increase in GGBFS replacement level. The compressive strength of concrete
increased when cement is replaced by GGBFS for both M20 and M40 grade of
concrete. At 40% replacement of cement by GGBFS the concrete attained maximum
compressive strength for bothM20 and M40 grade of concrete. The split tensile
strength of concrete is increased when cement is replaced with GGBFS. The split
tensile strength is maximum at 40% of replacement. The flexural strength of concrete
is also increased when the cement is replaced by GGBFS. At 40% replacement, the
flexural strength is maximum. The compressive strength values of acid effected
concrete decreases on comparison with of normal concrete, but the effect of acid on
concrete decreases with the increase of percentage of GGBFS. At 40% replacement of
GGBFS the resistance power of concrete is more. The compressive strength values
of GGBFS concrete effected to HCl were greater than the GGBFS concrete
effected to H2SO4. The effect of HCl on strength of the concrete is lower than the
effect of H2SO4 on strength of the concrete.

7] K.Prasanna et.al. The authors representing results on fly ash based geopolymer
concrete with GGBFS tested in compressive testing machine (100 Tonne capacity) to
determine their compressive strength at the age of 1 day, 7 days and 28 days of curing.
The main objective of this research was to produce a carbon dioxide emission free
cementious material. Although the geopolymer concrete is such and promising one it
has limitations of slow setting at ambient temperature and necessity of heat curing. In
this present study the main limitations of fly ash based geopolymer concrete are
eliminated by addition of Ground Granulated Blast Furnace Slag (GGBFS) powder
which shows considerable gain in strength utilizing Alkaline liquids for the
polymerization process are sodium hydroxide (NaoH) and sodium silicate (Na2Sio3)
solutions. Concrete is the most abundant manmade material in the world. However, the
production of cement is responsible for approximately 5%-8% of the world‟s carbon
dioxide emissions. In order to create a more sustainable world, a green building
material is essential thus the engineers and scientists found out Geopolymer concrete
which is much more durable that ordinary concrete due to its resistance to corrosion. It

8
is also much stronger than ordinary concrete. Geopolymer concrete is a revolutionary
sustainable building material that will pave the way for green building.

8] Paras S. Pithadiys et.al. The authors presenting study on effect of alkaline solution
ratio on GGBFS added geopolymer concrete. They are noted in his report based on
experimental work, it is observed that Geopolymer Concrete made with Fly ash and
Alkaline Solution Provides, a new era In the Construction Industry. With the Variation
of Alkaline Solution ratio there is gradual change in the Strength. For Compressive
Strength from 1.50 to 2.50 the Strength gradually increases but after that up to 3.50 it
goes decreases. For Tensile Strength, ratio of 2.0 shows the highest result and after
that the Strength value decreases. The amount of addition of GGBFS also plays an
important role for the Strength generation..addedGeopolymer Concrete .By the
Experimental Work, the Optimum Na2SiO3/ NaOH ratio for the Compressive
Strength is 2.50 and for the ratio of 2.50, increases in the Compressive Strength up to
60% than the ambient cured specimens. Oven Cured Specimens Shows Higher
Compressive Strength up to 59Mpa and Ambient Cured Specimens Shows up to 41
Mpa. For Tensile Strength the Optimum ratio is 2.0.There is Gradual increase in the
Strength from 10 % to 50% replacement of Fly ash by GGBFS.

9
 CHAPTER NO 3
MATERIALS AND SPECIFICATIONS
3.1 Materials used
1) Ground granulated blast furnace slag (GGBFS)
2) Ordinary Portland Cement (OPC)
3) Coarse Aggregate (CA)
4) Fine Aggregate (FA)
5) Water
6) Steel Fibre (SF)
7) Polypropylene Fibre

3.1.1 Ground Granulated Blast Furnace Slag (GGBFS)

In order to fulfill its commitment to the sustainable development of the whole society,
the concrete of tomorrow will not only be more durable, but also should be developed
to satisfy socioeconomic needs at the lowest environmental impact. So the problem is
related to environment, problem is related to cost minimization but structural engineer
will give the solution by proper analysing the properties of concrete made by using
industrial waste material. GGBFS means the ground granulated blast furnace slag is a
by-product of the manufacturing of pig iron. Iron ore, coke and Lime-stone are fed into
the furnace and the resulting molten slag floats above the molten iron at a temperature
of about 1500o C to 1600o C. The molten slag has a composition close to the chemical
quenched rapidly, resulting in the formation of a glassy granulate. This glassy
granulate is dried composition of Portland cement. After the molten iron is tapped off,
the remaining molten slag, which consists of mainly siliceous and aluminous residue is
then water- and ground to the required size, which is known as ground granulated blast
furnace slag (GGBFS).

10
 Fig.3.1: Sources of Ground Granulated Blast Furnace Slag.
The concrete made with such industrial wastes is ecofriendly and hence called as
“Green concrete”. It has been well known ground granulated blast-furnace slag
(GGBFS) can increase the abilities to prevent water penetration and chloride
penetration, and it can improve the durability of concrete structures (Ramezanianpour,
1995). Also, the use of GGBFS for concrete material contributes to the saving the
natural resources and energy in cement manufacturing process and to reducing CO2
emissions and environment impact. In Japan, GGBFS has been rarely used for bridge
superstructures because the increase of strength at early ages is smaller than that of the
concrete without GGBFS. While the some applications to pre-tensioned concrete have
been reported (Ishida, 2000) (Fukunaga, 2009), the application to post-tensioned
concrete has been very few. The more positive use of GGBFS has been required. One
of the possibilities to work out is the massive usage of industrial wastes like ground
granulated blast furnace slag (GGBFS) to turn them to useful environmental friendly
and technologically advantageous cementitious materials. GGBFS has been widely
used as a cement replacement material due to its latent hydraulic properties which
cannot directly react with water but requires an alkali activator. Ground Granulated
Blast Furnace Slag (GGBFS) is a by-product of the steel industry. Blast furnace slag is
defined as the non-metallic product consisting essentially of calcium silicates and
other bases that is developed in a molten condition simultaneously with iron in a blast
furnace. GGBFS is classified as a latent hydraulic material because it has both
pozzolanic and cementitious properties. Its latent hydraulic reactivity must be
catalysed by proper activators to form cementitious materials. The pozzolanic activity
of GGBFS is due to the presence of finely divided glassy silica and lime that produce
calcium silicate hydrates. The calcium hydroxide Ca(OH) provides the right
11
environment for pozzolanic action. The process is very slow and the particle sizes
below 45 micron are responsible for the pozzolanic reaction and higher size particles
act as a filler material. Therefore the replacement of cement by GGBFS is possible up
to certain extent and it can improve the durability of concrete structures. For complete
replacement of cement by GGBFS and to achieve higher strength within a short period
of time, it is possible to activate the GGBFS by using the alkaline solutions.
Geopolymer concrete is a new material in which cement is totally replaced by the
pozzolanic materials that is rich in Silicon (Si) and Aluminium (Al) like GGBFS. It is
activated by highly alkaline liquids to produce the binder which binds the aggregates
in concrete when subjected to elevated temperature. The chemical process involved in
this case is polymerization.
3.1.1.1. Physical and Chemical Properties of GGBFS
GGBFS produces a smoother, more defect free surface, due to the fineness of the
GGBFS particles. Dirt does not adhere to GGBFS concrete as easily as concrete made
with Portland cement, reducing maintenance costs. GGBFS cement prevents the
occurrence of efflorescence, the staining of concrete surfaces by calcium carbonate
deposits. Due to its much lower lime content and lower permeability, GGBFS is
effective in preventing efflorescence when used at replacement levels of 50% to
60%.The material has glassy structure and is ground to less than 45 microns in gray
colour. The surface area is about 350 to 600 m2 / kg Blaine. The ground slag in
presence of water and an activator which are commonly sulphates and /or alkalies
which are supplied by Ordinary Portland Cement react chemically with GGBFS and
hydrates and sets in a manner similar to Portland Cement.

Fig.3.2: GGBFS

12
The chemical composition of a slag varies considerably depending on the composition
of the raw materials in the iron production process. Silicate and aluminate impurities
from the ore and coke are combined in the blast furnace with a flux which lowers the
viscosity of the slag. In the case of pig iron production the flux consists mostly of a
mixture of limestone and forsterite or in some cases dolomite. In the blast furnace the
slag floats on top of the iron and is decanted for separation. The main components of
blast furnace slag are CaO (30-55%), SiO2 (22-36%), Al2O3 (6-24%), and MgO (1-
18%). In general increasing the CaO content of the slag results in raised slag basicity
and an increase in compressive strength. The MgO and Al2O3 content show the same
trend up to 10-12% and 14%, respectively beyond which no further improvement can
be obtained.
Table 3.1.Physical Characteristics of GGBFS.
Properties Values
Specific gravity 2.40
Fineness (m2 / kg) 439

Table 3.2.Chemical composition of GGBFS

Parameters Experimental Value %
Loss of ignition 0.70
Iron Oxide 1.0
Magnesium Oxide 10.0
Calcium Oxide 31.0
Silica 35.0
Aluminium Oxide 22.0

3.1.2 Ordinary Portland Cement (OPC)

Cement consists of four major compounds tricalcium silicate (C3S), Dicalcium silicate
(C2S), Tricalcium Aluminates (C3A) and Tetra Calcium Alumino ferrite (C4AF).
Tricalcium Silicate (C3S) and Dicalcium silicate (C2S) is the most important
compound responsible for strength. Together they constitute 70-80 percent of cement.
The average C3S content in modern cement is about 45 percent and that of C2S is
about 25 percent. During the course of reaction of C3S and C2S with water, calcium
silicate hydrate (C-S-H) and calcium hydroxide (Ca(OH)2) are formed. Calcium
13
silicate hydrates are the most important products and determines the good properties of
concrete. C3S readily reacts with water and produces more heat of hydration.
It is responsible for early strength of concrete. C2S hydrates rather slowly produces
less heat of hydration. It is responsible for later strength of concrete. The C3A portion
of cement hydrates more rapidly, thereby reducing the workability of fresh concrete.
Regarding particle size distribution, it may be noted that finer particles hydrate faster
than coarser particles and hence contribute more to early age strength; however, at the
same time, the faster the rate of hydration may lead to quicker loss of workability due
to rapid and large release of heat of hydration. After reviewing all above requirements
Ordinary Portland cement (OPC) of grade 53 cement is used throughout the
experimental work. Cement is tested in laboratory and is as follows:
1. Fineness test.
2. Standard Consistency test.
3. Initial and final Setting Time test.
3.1.2.1 Fineness Test
Fineness of cement determines the rate of hydration reaction. Finer cement reacts
faster with water and the rate of development of strength of corresponding heat of
hydration is higher. Fineness can be determined either by specific surface using air
permeability test or it can be determined by actual sieving.
3.1.2.2 Standard Consistency Test
This test in itself does not give any quality parameter of cement but it ascertains the
volume of water which is to be added for other tests like initial setting time, final
setting time, soundness and strength, etc.
3.1.2.3 Setting Time
Setting time means the time required for stiffening of cement paste to a defined
Consistency.
There are two limits on time scale which are important for setting of cement.
1. Initial setting time.
2. Final setting time.

3.1.3 Aggregates: - The aggregates are the main components of the concrete which
greatly varies the strength, density and other properties of the concrete. Different types
of aggregates used are discussed below.

14
3.1.3.1 Coarse and Fine Aggregates

Fig 3.3: Coarse Aggregate Fig 3.4: Fine Aggregate

The fine aggregate used in the study was river sand and coarse aggregate are crushed
angular granite stone passing 12.5 mm sieve. The sieve analysis of fine and coarse
aggregate are shown in table.

Table 3.3:- Sieve Analysis Results of Fine Aggregate

Sieve Wt. Cum % % Wt.

size retained Wt. passing Specifications as per IS 383: 1993 [133]
(mm) (gms) retained for % passing with different zones
I II III IV
4.75 001 00.10 99.9 90 - 100 90 - 100 90 - 100 90 - 100
2.36 023 02.40 97.6 60 - 95 75 - 100 85 - 100 95 – 100
1.18 129 15.30 84.7 30 - 70 55 - 90 75 - 100 90 – 100
0.60 328 48.10 51.9 15 - 34 35 - 59 60 - 79 80 – 100
0.30 406 88.70 11.3 5 - 20 8 - 30 12 - 40 15 – 50
0.15 094 98.10 01.9 0 - 10 0 - 10 0 - 10 0 – 15

15
 Table 3.4:- Sieve Analysis Results of Coarse Aggregate
Sr. Sieve Wt. % Wt. Cum % % Wt. Grading limits
NO Size retained retained Wt. passing as per IS 383:
(mm) (gms) retained 1993 [133]
1 20 0 0 0 100 100
2 12.5 200 4 4 96 90-100
3 10 1280 25.6 29.6 70.4 40-85
4 4.75 3200 64 93.6 6.4 0-10
Coarse and fine aggregate tested conforms to the specifications as per IS 383: 1970
[110] with fine aggregate belonging to zone II as per the specifications. The physical
characteristics of coarse and fine aggregates are shown in table.

Table 3.5: - Physical Characteristics of Coarse Aggregates

Sr.No Specific Gravity Fineness Flakiness Density (kg/m3)
Modulus Index loose Rodded
1 2.65 7.04 28.3% 1373 1535

Table 3.6: - Physical characteristics of Fine Aggregates

Sr.No Specific Gravity Fineness Flakiness Density (kg/m3)
Modulus Index loose Rodded
1 2.56 2.43 4.1% 1500 1675

3.1.4 Water
Water plays an active role in the chemical process of hydration and in curing concrete.
It is important ingredient of concrete as it actively participates in the mix design
consideration. The strength of concrete is mainly due to binding action of heat of
hydrated cement gel. The requirement of water should be reduced to that required for
chemical reaction of heat of hydration and required for workability. The excess water
form undesirable voids and capillary cavities in the hardened cement paste in concrete.

16
 It is necessary that water used for mixing and curing should be clean and free
from injurious material likes oils, acids, alkalis, salts, sugar, organic materials or other
substances that may be deleterious to concrete and steel. Drinking water is generally
considered satisfactory for mixing concrete.

3.1.5 Fibres
3.1.5.1 Steel Fibre
Steel Fibres Steel Fibre is a small piece of reinforcing material used as
secondary reinforcement. They can be circular or flat. The fibre is often described
by a convenient parameter called aspect ratio. The aspect ratio of the fibre is
the ratio of its length to its diameter. Steel fibres will reduce steel reinforcement
requirements, improve ductility, structural strength, reduce crack widths and
control the crack widths tightly thus improve durability, improve impact &
abrasion resistance, and improve freeze-thaw resistance.Steel fibres are used upto
0.5%, 1%, 1.5%, 2% by volume of cement concrete. There are different types of Steel
Fibres used in structural applications. They are Straight, Hooked and Crimped as
shown in Fig.

Fig 3.5: Steel Fibres

3.1.5.2 Polypropylene
Polypropylene fibres are the new form of chemical fibres. Addition of polypropylene
fibres decreases the unit weight of concrete and increases its strength. In this paper the
behaviour of the normal concrete and concrete with different types of fibres such as
macro-polypropylene and micro-polypropylene fibres have been studied. These fibres
were added to the concrete at 0.5%, 1%, 2% and 4% with respect to the volume of
concrete. Replacement of cement by a pozzolanic material, by-product from steel

17
manufacturing industries known as Ground Granulated Blast Furnace Slag (GGBFS).
The present study is to evaluate the mechanical properties of GGBFS as partial cement
replacement in micro and macro polypropylene fibre reinforced concrete. Cement
replaced with 40% GGBFS with 1% micro polypropylene fibre and 2% macro
polypropylene fibre shows higher compressive strength. Bond strength of various
mixes was determined by using pullout test.

Fig 3.6 : Polypropylene fibre

18
 CHAPTER NO 4
METHODOLOGY
4.1 Experimental Work
All test are conducted same as cement and instead of cement pozzolanic
material are used such as GGBFS along with Steel and Polypropylene Fibre in
different proportion and perform all test related to cement such as consistency,
soundness, initial and final setting time, strength of cement same as OPC. The
experiment is conducted one by one as follows. First one calculate consistency of
GGBFS for percentage of water require to next test such as soundness, initial and final
setting time and strength test.
In order to achieve the stated objectives, this study was carried out in few
stages. On the initial stage, all the materials and equipments needed must be gathered
or checked for availability. Then, the concrete mixes according to the predefined
proportions. Concrete samples were tested through concrete tests such as cube test.
Finally, the results obtained were analyzed to draw out conclusion.

4.2 Tests on Material

4.2.1. Test on Ordinary Portland Cement

4.2.1.1 Standard Consistency

 Unless otherwise specified this test shall be conducted at a temperature 27 +

20C and the relative humidity of laboratory should be 65 + 5%.
 Prepare a paste of weighed quantity of cement (300gms) with weighed quantity
of potable or distilled water, taking care that the time of gauging is not less
than 3minutes nor more than 5minutes and the gauging is completed before any
sign of setting occurs.

19
 Fig 4.1 Standard Consistency
 The gauging is counted from the time of adding water to the dry cement until
commencing to fill the mould.
 Fill the vicat mould with this paste resting upon a non-porous plate.
 Smoothen the surface of the paste, making it level with the top of the mould.
 Slightly shake the mould to expel the air.
 In filling the mould operators hands and the blade of the gauging trowel shall
only be used.
4.2.1.2 Initial and Final setting time
1. Take 400g of cement and place it in a bowl or tray.
2. Now add water of Start the stopwatch at the moment water is added to the
cement. Water of quantity 0.85P.times is considered.
3. Now fill the mix in Vicat mould. If any excessive paste remained on Vicat
mould is taken off by using a trowel.
4. Then, place the VICAT mould on non-porous plate (Glass plate) and see that the
plunger should touch the surface of VICAT mould gently.
5. Release the Plunger and allow it to sink into the test mould.
6. Note down the penetration of the plunger from the bottom of mould indicated on
the scale.
7. Repeat the same experiment at different positions on the mould until the plunger
should stop penetrating 5 from the bottom of the mould.

20
 Fig.4.2 Initial and Final setting time
The time period elapsed between the moment water is added to the cement and
the time, the needle fails to penetrate the mould of 5mm when measured from the
bottom of the mould, is the initial setting time of cement.
Now replace the needle (plunger) by the one with an annular attachment. The
cement is assumed as finally set When, upon applying the needle gently to the surface
of the test mould, the needle makes an impression therein, while the attachment fails to
do so. The time period between the moment water is added to the cement and the time
at which needle makes an impression on the surface of the mould, while the
attachment fails to do so, is the final setting time of cement.

4.3 Concrete Mix Design

Mix Design For M20 Grade Concrete
Design Stipulations:

1. Grade of concrete (designation) = M20

2. Type of cement = OPC 53 Grade
3. Minimum nominal size of aggregate = 20 mm
4. Workability = 75-100 mm
5. Exposure condition = Mild
6. Method of concrete placing = Normal
7. Degree of supervision = Good
8. Specific gravity of cement = 3.10
9. Specific gravity of coarse aggregate = 2.70

21
10. Specific gravity of fine aggregate = 2.56
11. Sieve analysis = Zone 2

Step 1: Target mean strength

Fck = Fck! +1.65S
= 20 +1.65 x 4
=26.6 N/mm2
Step 2: Selection of water cement ratio
From Table 5 of IS 456 - 2000
For M20 concrete, maximum w/c ratio = 0.5
Based on experience adopt water cement ratio =0.5
Step 3: Selection of water content
From Table 2, of IS 10262-2009
Maximum water content for 20 mm aggregate = 186 kg/m (for 25 to 50 mm slump)
Increase 3% of water content for every 25 mm slump range
To attain max of 100mm slump range =6% increase in water content
Estimated water content for 100mm slump =186+(6/100) (186)
=197.16 kg/m

Step 4: Calculation of cement content

Water cement ratio =0.5
Cement content =197.16/0.5
= 394.32 Kg/m
From Table 5. of IS 456 - 2000
Minimum Cement Content for 'mild" exposure condition 300 kg/m'
Above calculate cement content value is > 300 kg/m
Hence ok

Step 5: Volume of coarse aggregate & fine aggregate content

From table 3 of IS 10262-2009 Volume of coarse aggregate corresponding to 20 mm
size aggregate and fine aggregate (zone II)

22
For w/c ratio of 0.5 the volume of coarse aggregate per unit volume of total aggregate
is 0.48. Therefore, in the present case w/c ratio is 0.5, the corrected proportion of
volume of coarse aggregate is 0.47(w/c adjustment). As the water cement ratio is
increased by 0.05, the proportion of volume of coarse aggregate is decreased by 0.01
(at the rate of -/+ 0.01 for every 0.05 change in water cement ratio).
Volume of fine aggregate content = 1-0.62 = 0.38

Step 6: Mix calculations

Mix calculations percent volume of concrete shall as follows,
(a) Volume of concrete =1 m3

(b) Volume of Cement = Mass of cement x 10-3

Sp. Gravity of Cement
= (394.32÷3.10) x 10-3
= 0.127 m3
(c) Volume of Water = Mass of cement x 10-3
Sp. Gravity of Water
= (197.16÷1) x 10-3
= 0.197 m3
(d) Volume of all in aggr. = (a-(b+c ) )
= 1-(0127 +0.197)
= 0.676 m3
(e) Mass of coarse aggregate = (d x volume of coarse aggregate x sp gravity of
coarse aggregate x 1000)
= 0.676 x 0.62 x 27 x 1000
= 1159.61 kg
(f) Mass of fine aggregate = (dx volume of fine aggregate x sp
gravity of fine aggregate x 1000)
= 0.676 x 0.38 x 2.56 x 1000
= 669.527 kg

23
 Table No. 4.1 Mix Proportion For M20 Grade of Concrete
Sr. Steel Polypropylene
Cement GGBFS F.A. C.A. Water
No Fibre Fibre
m3 m3 m3 m3 m3
. m3 m3
1. 0.127 0 0.256 0.419 0. 197 - -
2. 0.114 0.013 0.256 0.419 0.197 0.005 0.005
3. 0.101 0.026 0.256 0.419 0.197 0.01 0.01
4. 0.088 0.039 0.256 0.419 0.197 0.015 0.015
5. 0.076 0.052 0.256 0.419 0.197 0.020 0.020

4.4 Casting of Moulds

Casting of following moulds was done -
1) Cube (Size -150 X 150 X 150) mm
2) Cylinder (Size -150 X 300 ) mm
3) Beam (Size- 150 X 150 X 750) mm

4.4.1 Casting of Cube

Procedure For Cube Casting
 Take random samples from the mix in a ghamela, while concreting.
 Pour concrete in the cubes in 3 layers.
 Compact each layer with 35 Nos. of strokes with the tamping rod.

Fig. 4.3 Standard Cube

24
  Finish the top surface by thapi /trowel after compaction of the last layer.
 Each specimen should be taken from different locations of the proposed
concreting
 After 24 hours, remove the specimen from the mould.
 While removing, take care to avoid breaking of the edges.
 Code the cube with paint or marker. Coding should be self explanatory,
building no. and the date of casting.
 Submerge the specimen in clean, fresh water until the time of testing.
 Test 3 specimens for 7 days & 3 specimens for 28 days curing.

Volume of single Concrete block

Volume of block = Length X Breadth X Height
= 0.150 X 0.150 X 0.150
= 0.003375 m3

25
4.4.2 Casting of Cylinder
Procedure
 After the mixture is prepared, it is poured into the oiled mould in layers
approximately 5 cm deep.
 Then, each layer is compacted either by hand or by vibration.
 For manual compaction, use tamping bar.
 Distributed bar stroke uniformly in order to compact it properly.
 Minimum tamping bar stroke for each layer is 30.
 Penetrate strikes in to the underlying layer
 Apply the rode for the entire depth of bottom layer
 complete top layer compaction
 Lastly, the surface of the concrete should be finished level with the top of the
mould, using a trowel and covered with a glass or metal plate to prevent
evaporation

4.4.3 Casting of Beams

Procedure
 Determine proportions of materials including cement, sand, aggregate and
water.
 Mix the materials using either by hand or using suitable mixing machine in
batches with size of 10 percent greater than molding test specimen.

26
 Measure the slump of each concrete batch after blending.
 Place molds on horizontal surface and lubricate inside surface with proper
lubricant material and excessive lubrication should be prevented.
 Pour fresh concrete into the molds in three layers.
 Compact each layer with 16mm rode and apply 25 strokes for each layer or fill
the mold completely and compact concrete using vibration table.
 Remove excess concrete from the top of the mold and smoothen it without
imposing pressure on it.
 Cover top of specimens in the molds and store them in a temperature room for
24 hours.
o
 Remove the molds and moist cure specimens at 23+/-2 C till the time of
testing.

 The age of the test is 7 days and 28 days and one specimens for each test
should be prepared (according to Indian Code, the specimen is stored in water
at 24-30oC for 48hours and then tested.
27
 Table No. 4.2 Casting Details
No. Of
Sr. No. Sample Type Testing Of Specimen
Specimen

7 days 28 days

1 Cube 5 5 10

2 Cylinder 5 5 10

3 Beam 5 5 10

4.5 Curing
The test specimen- shall be stored in a place, free from vibration, in moist air of at
least 90 percent relative humidity and at a temperature of 27° ± 2°e for 24 hours ± l
hour from the time of addition of water to the dry ingredients, After this period, the
specimens shall be marked and removed from the moulds and, unless required for test
within 24 hours, immediately submerged in clean, fresh water or saturated lime
solution and kept there until taken out just prior to test. The water or solution in which
the specimens are submerged shall be renewed every seven days and shall be
maintained at a temperature of 27° ± 2°C. The specimens shall not be alk.weo to
become dry at any time until they have been tested.

28
 CHAPTER NO 05
RESULT AND DISCUSSION
5.1 Compressive strength test
After measuring workability, concrete cubes of side 150 mm were cast in three
layers and each is properly compacted similar to cement concrete for 7, 28 a days.
Then after 24 h of casting, all cubes were demoulded and weight was taken for the
calculation of mass density. Average weight of three cubes was considered for
calculation of mass density. It is observed that the average mass density obtained by
proposed method is 2,801.48 kg/m3 which is 3.33 % higher than that considered in
design method. Then cubes were placed in an oven for thermal curing at 120°C for 7
h. To avoid sudden variation in temperature, the concrete cubes were allowed to cool
down up to room temperature in an oven itself. Three cubes were cast and tested for
compressive strength after 7 days , 28 days of test period. Here, test period is the
period considered after removing the cubes from oven till the time of testing for
compressive strength.
It is observed that the compressive strength of M20 grade concrete (100% OPC) is
tested 17.12 MPa after 7 days and 26.33 MPa for 28 days considered in proposed mix
design method which is within the limit of +/−15 % as per IS 456-2000.

Fig 5.1: Compressive Strength Test

29
5.1.1 Compression Test Results
Table No. 5.1 Compressive Strength of Cube.
2
2
FCK (N/mm ) at 28
MIX FCK (N/mm ) at 7 days
days
Only OPC 100% 14.82 20.93
GGBS (10%) 12.26 17.82
GGBS (20%) 16.45 22.07
GGBS (30%) 17.05 22.92
GGBS (40%) 18.92 26.60

5.2 Split Tensile Strength Test:-

Concrete cylinders of size 150 mm diameter and 300mm length were cast with
incorporating copper slag as partial replacement of sand and cement. During casting,
the cylinders were mechanically vibrated using a table vibrator. After 24 hours, the
specimens were demoulded and subjected to oven curing for 7 hours at 1200C in oven.
After curing, the cylindrical specimens were tested for split tensile strength using
compression testing machine of 2000kN capacity. The ultimate load was taken and the
average split tensile strength was calculated using the equation.

Fig 5.2: Split Tensile strength test

For the determination of splitting tensile strength of concrete, cylinder
specimens of diameter to length ratio 1:2 was selected. The use of GGBFS along with
steel fibre and polypropylene fibre as partial replacement of cement improved the
splitting tensile strength of concrete and showed variation in the strength when

30
10%,20%,30% s and 40% GGBFS ,SF and polypropelene used in the mixture. The
splitting tensile strength of various mixtures is shown in Fig.
Splitting tensile strength (ft) was obtained using the formula,
ft = 2P/ πDL (N/mm2)
Where, P = load at failure (N)
D = diameter of specimen (mm),
L = length of specimen (mm)
5.2.1 Split Tensile Strength Test Results

Table No 5.2 Split Tensile Strength of Cylinder

2
2
FCK (N/mm ) at 28
MIX FCK (N/mm ) at 7 days
days
Only OPC (100%) 0.45 2.83
GGBS (10%) 1.23 1.84
GGBS (20%) 0.88 1.98
GGBS (30%) 1.41 2.62
GGBS (40%) 1.37 2.62

5.3 Flexure strength test on beam:-

All beams were tested under two point loading system. The beams are simply
supported over a span of 600 mm and tested in a loading frame with capacity of 500
kN. Two steel rollers of 30 mm diameter were placed symmetrically over the beam on
at the distance of 1/3rd of span from left and right side of the support. The steel beam
ISMB 250 is provided over the roller to transfer the load on the beam through rollers.
Hydraulic jack with capacity of 500 kN is placed centrally over the beam and channel.
Three number of digital dial gauge used to measure the deflection. One placed at mid
section of the beam and two were placed at 1/6th span from left and right side of the
support. The test configuration is shown in Figure.

31
 Fig.5.3 Flexural Strength Test
Standard beams of size 150 x 150 x 750 mm were supported symmetrically
over a span of 600 mm subjected central point‟s loading acting by UTM till failure of
the specimen. The Geopolymer concrete mixtures were used for the flexural strength.
Tests carried on 150 X 150 X 750 mm specimens.
5.3.1 Flexural Strength Test Results
Table 5.3 Flexural Strength of Beam
Avg
% GGBFS Avg Avg Flexural
Sr
Designation Replacement Load Deflection Remarks Strength
No.
of Cement (KN) (mm) of Beam
at 28 day
First crack
26 0.77 load and
Conventional 16.35
1 0 deflection
Beam N/mm2
Ulti. Load &
93 2.76
Deflection
First crack
29 1.11 load &
GGBFS 19.31
2 40 deflection
Beam N/mm2
Ulti. Load &
112 3.93
Deflection

32
 CHAPTER NO 06
CONCLUSIONS
 Blast Furnace Slag concrete mix having various cement replacement level up
to 40% Exhibited satisfactory results for compressive strength.
 The optimum use of GGBFS along with steel and polypropylene Fibre upto
certain percentage of cement replacement gives higher compressive ,split
tensile and flexural strength.
 Use of high volume GGBFS as a replacement of cement, in any construction
work, provides Lower impact on environment (reduced CO2 emission) and
judicious use of resources(energy conservation, use of by-product etc.)
 Use of GGBFS reduces the amount of cement content as well as heat of
hydration in a mortar mix. Thus, the construction work with GGBFS concrete
becomes economical and also environmentally safe.
 The optimum dosage for partial replacement of cement by ground granulated
blast furnace slag is 40%
 The optimum dosage for addition of steel fibred is 2%
 The percentage of increase in compressive strength for M20, grade for partial
replacement of cement by GGBS (40%) + addition of steel fibre and
polypropylene (2%) are nearly same for other proportion of GGBFS,steel and
polypropylene.
 Test results reveal that higher fibre content has brought about increased
compressive strength, flexural strength, and fibre crack-control effect. Hence
the addition of steel fibre within FRC is more helpful for the flexural strength
than the compressive strength.
 Cement replaced with 40% GGBFS with 1% micro polypropylene fibre and
2% macro polypropylene fibre shows higher compressive strength.
 In splitting tensile strength test, it was found that tensile strength was
significantly improved only for 0.5% of fiber dosage and as the percentage of
fiber volume dosage increases a continues drop of strength was observed.
 In flexure strength the improvement in the behavior due to the addition of the
PPF is the similar to that in tensile strength. Hence we may conclude that the
optimum value of fibre content is 0.5% for both tensile strength and flexural
strength.
33
 As per the current demand of construction industry new types of concrete are
to be invented, which will satisfy the problems observed in traditional concrete.
In this approach PPFC will be a good substitute to meet the present demand of
construction industry.

34
 REFERENCES

 Santosh Kumar Karri,G.V.RamaRao, P.MarkandeyaRaju “Strength and

Durability Studies on GGBFS Concrete” (SSRG-IJCE) – volume 2 Issue 10
October 2015.
 Prof Siddharth, Prof. Seetharam.Munnur,” Experimental Study on
Strength Properties of Concrete using Steel Fibre and GGBFS as Partial
Replacement of Cement”, International Journal of Engineering Research
& Technology (IJERT) ISSN: 2278-0181Vol. 4 Issue 01,January-2015
 S.P.Sangeetha, P.S Joanna,”Flexural behaviour of Reinforced concrete beams
with partial replacement of GGBFS”, AJER,e-ISSN: 2320-
0936,Volume3,Issue01,pp-119-127,2014.
 Premlal. V G,Prof. A. Nizad, “Strength and Durability Characteristics of
Steel Fibre Reinforced Concrete Containing Copper Slag as Partial
Replacement of Fine Aggregate”, International Journal of Engineering
Research & Technology (IJERT) ISSN: 2278-0181Vol. 4 Issue 09,
September-2015
 M. Pavan Kumar, Y. Mahesh, “The Behaviour of Concrete by Partial
Replacement of Fine Aggregate with Copper Slag and Cement with GGBFS -
An Experimental Study” IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE) e-ISSN:2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 3
Ver. III (May. - Jun. 2015), PP 51-56
 D. Suresh and K. Nagaraj,” Ground Granulated Blast Slag (GGBFS) In
Concrete – A Review” IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE),e- ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 4
Ver. VI (Jul. - Aug.2015), PP 76-82”.
 Danying Gao (2012) - D Gao, D Yan, X Li - Fire safety journal, 2012 –
Elsevier.
 V. Awasare, “Analysis Of Strength Characteristics Of GGBS,” pp. 1–3, 1987.
 R. Rughooputh and J. Rana, “Partial Replacement of Cement by Ground
Granulated Blast furnace Slag In Concrete Corresponding Author : Reshma
Rughooputh,” vol. 5, no. 5, pp. 340–343, 2014.

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 S. K. Gadpalliwar, R. S. Deotale, and A. R. Narde, “„ To Study the Parti al
Replacement of Cement by GGBS & RHA and Natural Sand by Quarry Sand
I n Concrete ,‟” vol. 11, no. 2, pp. 69–77, 2014.
 S. M. Sowmya, P. Kumbar, and R. Amar, “An Experimental Investigation on
Strength Properties of Concrete by Replacing Cement with GGBS and Silica
Fume Abstract :,” no. 8, pp. 191–201, 2014.
 H. L. Chaithra, K. Pramod, and A. Chandrashekar, “An Experimental Study
on Partial Replacement of Cement by Ggbs and Natural Sand by Quarry Sand
in Concrete,” vol. 4, no. 5, pp. 1539–1544, 2015.
 K. Wangchuk, K. Tsheten, and K. Yezer, “Construction : The Challenge For
The,” pp. 142–146, 2013.
 R. Jin, Q. Chen, and D. Ph, “An Investigation of Current Status of „ Green ‟
Concrete in the Construction Industry,” 2013.
 P. Mahabir and B. K. Chandra, “Effect of Synthetic Fibres on Concrete with
GGBFS Replaced Cement.”
 N. Givi, A. N. Givi, S. A. Rashid, F. N. A. Aziz, M. Amran, and M. Salleh,
“Contribution of Rice Husk Ash to the Properties of Mortar and Concrete : A
Review,” vol. 6, no. 3, pp. 157–165, 2010.
 H. M. Owaid, R. B. Hamid, M. R. Taha, S. Engineering, S. Engineering, and
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36
 ANNEXURE A

PAPERS PRESENTED IN CONFERENCES

Level Of
Name Of
Name of The Conference
No Title Of Paper Conference &
Author(S) (State/Internat
Organised By
ional)
Partial Replacement Of
1. Gawade Gopinath B. Cement By Ground
Recent Trends In
2. Gunjal Ashish B. Granulated Blast
Science And
1. 3. Shinde Omkar P. Furnance Slag (GGBFS) STATE LEVEL
Technology by
4. Bhalerao Mangesh B. Along With Steel And
SGOI COE,Belhe
Polypropylene Fibre In
Concrete
Partial Replacement Of
Cement By Ground
1. Gawade Gopinath B. Recent Trends In
Granulated Blast
2. Gunjal Ashish B. Science And
2. Furnance Slag (GGBFS) STATE LEVEL
3. Shinde Omkar P. Technology by
Along With Steel And
4. Bhalerao Mangesh B. SGOI COE,Belhe
Polypropylene Fibre In
Concrete

37
ANNEXURE B

CERTIFICATES

38
39
40
41
42
43
44
45