RAPID SETTING SOREL CEMENT WITH M-SAND – STRENRTH …

IRACST – Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498, Vol.3, No.2, April 2013

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RAPID SETTING SOREL CEMENT WITH M-SAND – STRENRTH AND WORKABILITY ASPECTS

K.J.SAM PAUL JEBA NIM, S.Manjuladevi Dr.S.Senthilkumar Department of Civil Engineering, Department of Civil Engineering, Department of Civil Engineering Karunya University, Karunya University, K.S.Rangasamy College of Engineering, Coimbatore‐641114, Coimbatore‐641114, Tiruchengode‐637215 Email: [email protected] Email: [email protected] Email : [email protected]

ABSTRACT -- There is a great interest in the improvement, properties and implementation of alternatives to Portland cement as a binder in concrete and also alternatives to fine and coarse aggregates in concrete. To reduce the energy used in production of Portland cement clinker and the associated greenhouse gas emission. Magnesium phosphate cements (MPCs) have been extensively used as fast setting cements in civil engineering. They have properties that are also similar to biomedical applications, such as fast setting and early strength. The cements were prepared by mixing magnesium oxide (MgO) with either sodium dihydrogen phosphate(NaH2PO4) or ammonium dihydrogen phosphate (NH4H2PO4). In this study, the effect of varying percentages of fly ash with M-sand on compressive strength of high performance concrete has been evaluated. All the percentages have been studied in terms of compressive strength and flexural strength. Keywords – Concrete, Magnesium phosphate Cement, M- sand, fly ash.

1. INTRODUCTION

Concrete is a widely used construction material for various types of structures due to its durability. For a long time it was considered to be very durable material requiring a little or no maintenance. Many environmental phenomena are known significantly the durability of reinforced concrete structures. We build concrete structures in highly polluted urban and industrial areas, aggressive marine environments and many other hostile conditions where other materials of construction are found to be nondurable. In the recent revision of IS:456-2000,one of the major points discussed is the durability aspects of concrete. So the use of concrete is very essential. At the same

time the scarcity of aggregates are also greatly increased nowadays. Utilization of industrial soil waste or secondary materials has been encouraged in construction field for the production of cement and concrete because it contributes to reducing the consumption of natural resources. For many years, by products such as slag, silica fume and fly ash were considered as waste materials. In the construction industry they have been successfully used for partial or full replacement for fine and coarse aggregates

II. MATERIALS

A. FLY ASH Fly ash is finely divided residue resulting from the combustion of powdered coal and transported by the flue gases and collected by electrostatic precipitator. Fly ash is the most widely used pozzolanic material all over the world. Fly ash was first used in large scale in the construction of Hungry Horse dam in America in the approximate amount of 30 per cent by weight of cement. The use of fly ash as concrete admixture not only extends technical advantages to the properties of concrete but also contributes to the environmental pollution control. The fly ash can be used by two ways: one way is to intergrind certain percentage of fly ash with cement clinker at the factory to produce Portland pozzolana cement (PPC) and the second way is to use the fly ash as an admixture at the time of making concrete at the site of work ASTM broadly classifies fly ash into two classes. Class F: Fly ash normally produced by burning anthracite or bituminous coal, usually has less than


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5% CaO. Class F fly ash has pozzolanic properties only. Class C: Fly ash normally produced by burning lignite or sub-bituminous coal. Excess of 10% CaO content may have been in class C fly ash. In addition to pozzolanic properties, class C fly ash also can possesses cementitious properties. B.MAGNESIUM PHOSPHATE CEMENT: Magnesium-Phosphate Cement is a blend of magnesium oxide (MgO) and ammonium dihydrogen phosphate (NH4H2PO4) or alkali phosphate salt such as sodium or potassium phosphate or an agricultural fertilizer solution known as 10-34-0 (NPK designation) can also be used. Rapid hardening but long enough setting time to cast, high early strength, good bond, and compatibility with old concrete. This type of cement can obtain several thousand psi compressive strength in 1 hr. These materials are usually applied for repairing the surface damage of many concrete structures such as highway pavements, airport runways, bridge decks, key municipal roads, and other concrete structures rapidly.

1) Process : The phosphate-cement process is based on an acid-base reaction. Here we describe the process based on monopotassium dihydrogen phosphate (KH2PO4). The reaction product is magnesium phosphate (MgKPO4. 6H2O) that is formed by dissolution of MgO in the solution of KH2PO4 and its eventual reaction to form the product according to the reaction:

MgO + KH2PO4 + 5H2O → MgKPO4. 6H2O

Figure 1.Magnesium Oxide(Mgo)

Figure 2.Ammonium phosphate salt

Figure 3.magnesium phosphate cement(MPC)

C. M- SAND: • Increasing cost of natural sand

• Easy availability of msand

• When used a good quality msand it

is said that there is an increase in

strength by 10% than natural sand

• Cheaper than natural sand

Table 1 .Properties of M-sand:

III. SEM ANALYSIS

A scanning electron microscope (SEM) produces images of a sample by scanning it with a focused beam of electrons. These electrons interact with electrons in the sample, producing various signals

Properties values

Fineness modulus 2.4

Specific gravity 2.67

Water absorption 1%

Rodded bulk density 1.85g/cc

Grading zone II


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which contain information about the sample's surface topography and composition. SEM can achieve resolution better than 1 nanometer.

Fig 1: sem images of Magnesium Oxide

Fig 2: SEM images of ammonium dihydrogen phosphate

IV. MIX DESIGN In table 2, the details of the mix design are given. Table 2 : Mix design of concrete using IS 10262:2009

M25 M30 material Quantity

(Kg/m3) Mix ratio

Quantity (Kg/m3)

Mix ratio

Cement 425.78 1 445 1 Fine aggregate

685 1.6 670 1.5

Coarse aggregate

1209 2.8 1186 2.6

Water 191.6 .45 191.6 .43

V. EXPERIMENTAL INVESTIGATIONS

Basic tests to find out the physical properties of various ingredients in blended cement concrete have been conducted to continue the thesis. The results of the various tests are tabulated and the comparisons are produced in graphical form in the following session.

A. Consistency Test

Table 3 : consistency test results

B.Initial Setting Time

Table 4 : Initial setting time result

C.Properties of Fine Aggregate

Table 5: Properties of fine aggregate

D.Properties of Coarse Aggregate

Table 6: Properties of coarse aggregate

Components value

Ordinary Portland cement 34%

Blended cement (25% OPC + 50% MPC +

25% fly ash)

42%

Components Value Ordinary Portland cement 30 minutes

Blended cement (25% OPC + 50%

MPC + 25% fly ash)

25 minutes

Property River Sand M-Sand

Specific gravity 2.79 2.82

Loose density 1.87 g/cc 1.94 g/cc

Rodded density 1.87 g/cc 1.94 g/cc

Grading Zone II II

Property Coarse aggregate

Specific gravity 2.75

Density 1.58 g/cc


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E.Tests on Strength

Compressive Strength of Cement (N/mm2)

Fig 4: Comparison of strength development of Cement using river sand and M-Sand

Fig 5: compressive strength of cement.

Compressive Strength of Concrete (N/mm2)

Fig 6: Comparison of Cube compressive Strength of

M25 concrete between OPC and blended cement with

M-Sand

Fig 7:Comparison of Cube compressive Strength of

M30 concrete between OPC and blended cement with

M-Sand


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Fig 8: compressive strength of concrete testing setup for cylinder

Fig 9: Comparison of Cylindrical compressive Strength of M25 concrete between OPC and blended

cement with M-Sand

Fig 10: Comparison of Cylindrical compressive Strength of M30 concrete between OPC and blended

cement with M-Sand Split tensile Strength of Concrete (N/mm2)

Fig 11: Comparison of split tensile Strength for M25 grade concrete between OPC and blended cement

with M-Sand

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Fig 12: Comparison of split tensile Strength for M30

grade concrete between OPC and blended cement with M-Sand

Test on Durability – Alkalinity Test Table 7: pH value of concrete

Concrete grade pH value

M25 10.8

M30 11.2

blended cement concrete 11.9

CONCLUSION

1. A detailed review of literature was done to study the various properties of MPC and fly ash. Various tests on cement, fine aggregate and coarse aggregate was carried out.

2. Compressive strength of mortar cubes with blended cement and M-sand was found to be increased by 7% than mortar cubes with

OPC at 28th day testing. 3. Cube Compressive strength of blended

cement concrete with M-sand was found to be increased by 45% than conventional

concrete for M25 and 21% for M30 at 28th

day testing. 4. Cylindrical Compressive strength of blended

cement concrete with M-sand was found to be increased by 33% than conventional


day testing. 5. Split tensile strength of blended cement

concrete with M-sand was found to be increased by 25% than conventional


day testing. 6. The pH value of blended cement

concrete,M25 and M30 conventional concrete are 11.9,10.8 and 11.2 respectively.

REFERENCES

[1] Patel, A.A and D.A. Sinha, An experimental

investigation on effect of fly ash and metakaolin on steel fibre reinforced concrete at temperature upto 200 deg Celsius.

[2] Aggarwal, V., S.M. Gupta and S.N. Sachdeva, 2012. Investigations on fly ash concrete for pavements. Int. J. Civil Struct. Eng., 2 (3): 876 – 883.

[3] Kogbara, R.B., S.R. Iyengar and A. Al-Tabbaa, 2011. Utilisation of magnesium phosphate cements to facilitate biodegradation within a stabilised/solidified contaminated soil. Water, Air, & Soil Pollution, 216 (1-4), 411 – 427.

[4] Swanson, G. Magnesium Oxide, Magnesium Chloride and Phosphate-based Cements. Available: http://www.greenhomebuilding.com/pdf/MgO-GENERAL.pdf

[5] Li, Z., Z. Ding and Y. Zhang, 2004. Development of sustainable cementitious materials. Proc. Int. Workshop on Sust. Dev. And Concr. Technol., Beijing, China.

[6] Koyama, T., Y.P. Sun, T. Fujinaga, H. Koyamada and F. Ogata, 2008. Mechanical properties of concrete beam made of a large amount of fine fly ash. 14th World Conf. on Earthquake Engrg., Beijing, China.

[7] Banchhor, A. and S. Krishnan. Advantages of using Fly Ash in Concrete PPC or site mixing of OPC and fly ash site. Available: http://www.sefindia.org/forum/files/opc_ppc_fly_ash_study_jan_06_by_mr_anil_banchhor_and_mr_s_krishnan_241.pdf

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RAPID SETTING SOREL CEMENT WITH M-SAND – STRENRTH …