CHAPTER-III
EXPERIMENTAL PROGRAM
3.0 INTRODUCTION
Reactive powder concrete (RPC) has initiated an interest and
possibility of expecting ultra high performances from commercially
available materials. They possess ultra high strength and high ductility
with advanced mechanical properties and consist of a specific
microstructure, which was optimized by precise gradation of all
particles in the mix to yield maximum density. It uses extensively the
pozzolanic properties of highly refined silica fume and optimization of
the Portland cement chemistry to produce the high strength hydrates.
The properties of hardened Ultra High Performance Concrete (UHPC)
were determined by the very dense structure of this material. The
microstructure of UHPC differs significantly from normal- and highstrength concrete. With respect to the mechanical behavior, UHPC with
fibres shows, depending on the type and quantity of fibres contained in
the mix, ductile behavior under compression as well as in tension. In
contrast to this, UHPC without fibres behaves brittle, if no additional
measure such as confinement is chosen. Since the pre-peak behavior
does not show significant differences, the elastic properties of UHPC
with and without fibres can be described, in common whereas the
influence of fibres has to be described separately. By introducing fine
steel fibres, they can exhibit remarkable strengths and energy
absorptions. However, lot of research works were carried out for the
38
production of RPC, which is an UHPC, very few studies, precisely
compares in detail their mechanical properties with UHPC. In addition,
the role of fibre addition on the compressive and flexural strengths of
RPC is required to understand and set optimum limits on the fibre
content.
This chapter presents the details of development of Reactive Powder
Concrete and the various test programs conducted. The study is aimed
at identifying and optimizing the salient parameters that influenced the
mixture proportions of the Reactive Powder Concrete and its curing
methods. Also, study of various mechanical properties of RPC is carried
out to find the feasibility of using RPC as structural components such
as angle sections. The various test programs are as follows.
3.1
EXPERIMENTAL SCHEDULE
Production
of
RPC
with
target
compressive
strength
of
characterization
Mechanical properties
by
conducting
studies
on
following
39
i. Study of compressive strength of RPC
ii. Stress-strain characteristic of RPC under compression
iii. Study of Tensile Properties of RPC by conducting
a)Direct tension test using Dog-bone shaped specimen
b) Evaluating the cracking behavior of RPC under tension using
the micro-mechanical modeling technique.
iv. Three point bending test
v. Shear strength
6. Investigation on use of RPC for specific Applications
i.
iii.
Performance
Evaluation
of
RPC
infilled
tubes
under
Compression.
7. Investigation on Connection Details.
i.
40
size of aggregates used for RPC is 2.36mm respectively. Based on size
of aggregates, two lengths of micro steel fibres were used 6mm, and
13mm micro-steel fibres (for RPC). Eventually the workability was
controlled using adequate quantities of third generation poly-carboxylic
based superplasticizers. The properties of these fibres are shown in
Table 3.4. The mix proportions used for the production of RPC are
tabulated in Table 3.5.
3.3 FORMULATION AND PROPERTIES OF RPC
A Reactive Powder Concrete formulation developed at the Structural
Engineering
Research
Center,
Chennai,
based
on
extensive
41
5. Quartz sand
6. Poly-acrylic ester type Super plasticizer
7. Steel fibre of diameter 0.16mm and length 13mm & 6mm having
tensile strength of 2000MPa.
3.4 PREPARATION OF RPC MIX
The standard mix proportion and quantity of materials per m 3 of
reactive powder concrete mix formulation developed at CSIR-SERC,
Chennai is shown in Table 3.5.
42
ingredients were mixed thoroughly with water and Super
plasticizer (SP) and when flowable consistency was achieved, the
fibres were added to the mixing bowl slowly with the mixer
operating in low gear. Care was taken to ensure random
distribution of fibres. The speed was increased and further
mixing was carried out by incorporating additional SP, if
necessary, to account for the possible stiffening of mixture due to
fibre addition.
43
differences in the relative size of steel fibres with respect to the
maximum size of the coarse aggregate. In usual fibre reinforced
concrete, steel fibre length is of the same order at the maximum size of
coarse aggregate, creating a strong interference with the aggregates.
That is why it was always recommended to slightly decrease the
maximum size of the coarse aggregate in steel fibre reinforced concrete
and to increase the sand content. On the contrary, there is no such
interference in RPC because the steel fibres are 20 times longer (13mm)
than the coarser aggregate (600m). As a comparison, keeping the
same aspect ratio, adding steel fibres to RPC like adding 400mm long
rebar to a normal concrete made with a 20mm coarse aggregate.
The physical properties such as density, water absorption and air
voids were determined as per ASTM C 642 already tested and
confirmed at CSIR-SERC while formulating the mix proportion. In
addition, the ultrasonic pulse velocity (UPV) measurements were taken
using the PUNDIT apparatus as per ASTM C 597 procedure. The fresh
and physical properties of the RPC mixtures were tabulated in Table
3.6.
44
Table 3.1 Chemical composition of powders
Oxides
Sio2
Al2O3
Fe2O3
CaO
MgO
Na2O
K2O
TiO2
Mn2O3
SO3
Free Lime
Chlorides
LOI
Portland
cement
20.49
5.91
4.07
62.90
1.13
0.20
0.47
0.20
0.08
1.87
0.45
0.012
2.29
Silica
fume
94.73
_
_
_
0.51
_
_
_
0.2
_
0.07
1.5
Materials Used
Sym
1.
Cement
2.
Silica Fume
SF
Properties
OPC: 53 Grade; SG
= 3.15; SC = 28%;
IST = 110 min; FST
= 260 min; CS = 58
MPa at 28 days
SG = 2.25; %
Passing through
45m sieve in
WSA=92 %.
SG = 2.59; %
Passing through
45m sieve in
WSA=75 %
Super Plasticizer
SP
Micro-steel fibres
STF
SG = 2.63
Poly-Acrylic Ester
Based
L=6, and 13 mm &
D=0.16mm
3.
Quartz Powder
4.
Ennore Sand
5.
6
Note: OPC Ordinary Portland cement, SG Specific Gravity, CS Cube Strength, PSR Particle
size range, SC Standard Consistency, WSA Wet sieve analysis of aggregates, L Length, D
Diameter.
45
Particle size(m)
Specific
gravity
Powders
D10
D30
D50
D60
Cement
3.15
49
33
21
14
Quartz
2.59
47.5
31.75
19.5
13.8
Silica
fume
2.2
0.55*
3*
7*
9*
* Higher average particle size of silica fume is due to use of fused silica fume
Type of fibres
Beakaert carbon straight micro-steel
fibres
Dimension of fibre
L(mm)
D(mm)
6
0.16
13
Strength
MPa
2000
SF
0.25
SF
kg
194
C
1
Q
FA
w/c
0.4
1.1
0.22
Quantity of Materials / m3
C
Q
Sand
w/c
kg
Kg
kg
l
777
311
855
171
SP
STF
3
0.2 (2% by vol.)
of concrete
SP
STF
L
kg
29
160
46
Table 3.6 Fresh and Physical Properties of the Mixtures
Types of Concrete
Flow
Density(kg/m3)
Porosity(%)
RPC
135
2297
4.25
RPC-1% 6mm
110
2341
2.95
RPC-2% 6mm
105
2378
3.1
RPC-3% 6mm
100
2549
0.65
RPC-1% 13mm
110
2385
2.85
RPC-2 % 13mm
90
2415
3.82
47
300
Temper
ature
(C )
250
ROC: 1 hr
200
ROH: 1 hr
150
HAC
100
ATC
50
NWC
0
0
10
48
shown in Table 3.8. The static modulus of elasticity was determined
from compression test as per ASTM C 469 procedure using 100 x 200
mm cylinders for RPC. All the tests were conducted after 28 days of
respective curing cycles. The toughness characteristics of these
concretes were calculated by first plotting the flexural strength deflection plot and then calculating the area under the plot. The
toughness index was calculated at different deformation levels namely
I5, I10 and I20 as per ASTM C 1108. The energy absorption characteristic
was conducted for RPC concretes by first plotting the stress-strain
curve in compression and then determining the area under the stressstrain plot. Table 3.9 gives the mixture proportions of RPC mixtures
with different fibre contents and Table 3.6.
Table 3.7 Experimental program
Fibre
Mix ID
RPC
RPC - 1%
RPC - 2%
RPC - 3%
RPC - 1%
RPC - 2%
RPC - 3%
RPC 1%+1%
RPC 1%+2%
Compressio
n
Fle
xur
e
Toughne
ss
Energy
absorption
Direct
tension
0
1
2
3
1
2
3
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
_
_
C
C
C
C
C
_
6+13
6+13
Length
(mm)
6
6
6
13
13
13
C Tests Conducted
49
Table 3.8 Tests conducted to study the Mechanical Properties of
RPC
Tests
Compression
Properties
studied
Type of
concrete
Standards
Specimen size
Stress-strain plot
& Energy
absorption
ASTM C 469
100 x200 mm
cylinder
Direct tension
RPC
Flexure and
toughness
RPC
ASTM C 348
Tension
Briquettes
shape(dogbone shape)
70x70x350
mm prism
Mix ID
Fibre Length
RPC
RPC -1%
6mm
0.25
0.4
1.1
0.17
RPC -2%
6mm
0.25
0.4
1.1
0.17
RPC - 3%
6mm
0.25
0.4
1.1
RPC - 1%
13mm
0.25
0.4
RPC -2%
13mm
0.25
RPC - 3%
13mm
6mm+13mm
6mm+13mm
RPC1%+1%
RPC1%+2%
0.20
1.2
2.2
5
2.5
1.1
0.17
1.2
0.4
1.1
0.17
0.25
0.4
1.1
0.20
2.2
5
2.5
0.25
0.4
0.25
0.4
1.1
1.1
2
3
0.17
2.2
5
0.20
2.5
50
3.7 PREPARATION OF TEST SPECIMENS
3.7.1. Preparation of Compression Specimens
The RPC cylinders of 100mm diameter and 200mm height were cast
with various fibre content and combinations as follows.
i.
1% of 6mm fibres
ii.
2% of 6mm fibres
iii.
3% of 6mm fibres
iv.
1% of 13mm fibres
v.
2% of 13mm fibre
vi.
vii.
51
middle portion as used in the experiments appears to be, at least
theoretically, the most appropriate geometric shape needed to avoid
local stress concentration.
To overcome the problems associated with specimen grips, end
tapered specimen were tested in tension. The geometry of typical
specimen was shown in Fig.3.4. The cross section in the constant
width portion is 200mm. The overall height of the specimen was
350mm and both end edge is 150mm. Special steel moulds were
designed and fabricated for the preparation of direct tension test
specimens. The tension tests were carried out on Dog-bone shaped
tensile specimens with notches 10mm deep 2mm wide cut at middle
length.
52
Fig. 3.6 Over All View of Tension Specimen with various fibre dosages
53
3.7.3 Preparation of Flexure and shear Specimen
RPC beams of size 70 x 70 x 350 mm with different lengths of fibres
[l/d (mm), 6/0.16, 13/0.16] single or in combination and different
volume fractions were prepared and tested.
Fig.3.7
Fig. 3.8
ID
1
2
3
4
5
6
R0
RS2
RD21
RD32
RS2L
RS3L
13mm
0
2
2
3
0
0
0
0
1
2
2
3
54
5mm. The notch was formed by embedding an acrylic plate of the 5mm
thickness during casting. Adequate measures were taken to prevent
bonding between the plate and concrete. The specimens shall be
subjected to testing in a condition immediately after completion of the
specified curing procedure.
3.7.4 Preparation of test specimen for Bolted Plates
A Reactive Powder Concrete formulation developed at the Structural
Engineering
Research
Centre,
Chennai
based
on
extensive
55
3.7.5 Preparation of Angle Specimens
3.7.5.1
For casting the RPC angles, a special device was designed and
fabricated as shown in the Fig-3.10. Using the special mould angle
sections of 80mm x 80mm x 10mm angle sections were cast for 1m
length. Then the angle sections were cut to different heights or lengths
to conduct the flexure and compression tests. The mould consists of
two V-shaped plates, one fixed and the other one movable, which is
fitted with a handle. The concrete is placed on the fixed angle and
pressed against, by the movable angle plate. A plate with bolt holes is
fixed at the bottom angle mould to fix the thickness of angle sections.
The thickness of the angle sections can be adjusted, by fixing the
moving angle mould to the corresponding bolt holes fixed at the bottom
angle mould. With this mould one can cast angle sections of thickness
5mm, 6mm, 8mm, 10mm, 12mm, 14mm, 16mm and 20mm.
The following describes the specimens used in this study for
determining
the
mechanical
properties
of
various
RPC
angles.
56
57
Fig. 3.11(a)
Fig. 3.11(b)
58
pressure is transferred through the movable angle to the materials in
the base fixed angle mould. Fig.3.10, Figs.3.11 (a) &3.11(b) shows the
details and photographic view of the device.
The entire loading device was placed on the table vibrator. The well
mixed RPC mixture was poured in the female angle mould to uniform
thickness. The male angle was lowered up to touch the RPC material
placed in the female angle by rotating the vertical shaft. Vibration was
applied on the entire device. Simultaneously vertical pressure was
applied through the male angle to the material in the female mould.
The thickness guides were fixed on both sides of the female mould.
Pressure was applied until the male angle reaches the thickness guide.
The excess material if any was squeezed out through the gap between
the guide and the male angle. The thickness of the RPC angle product
was possible from 5mm to 20mm. After 24 hours, the pressure on the
material was released by raising the male angle. The specimen was
removed from the female mould and cured by the standardised curing
regime (Fig. 3.2).
3.7.6 Preparation of Reactive Powder Concrete Infilled Tubes
The mix proportion for the infill and the quantity of material used
per m3 of reactive powder concrete mix formulation are as per the Table
3.2 and 3.3.
59
3.7.6.1 Details of Reactive Powder Concrete infilled tubes(RFIT)
Specimens Used
Hollow tubes
In filled Steel tubes
3
9
60
properly compacted by a table vibrator. A 10 mm aluminium tube was
provided at the centre of the steel tube, for inserting the 7 mm
prestressing wire. The inside portion of the steel tube is shown in Fig
3.13.
Fig. 3.13
Fig 3.13 Inside Portion of the Steel Tube
Fig 3.14 Steel Plate
Fig. 3.14
After the casting, the steel tube is closed with a plate with a central
hole (Fig. 3.14). A central hole was made in the plate for the insertion
of the pre-stressing wire. The pre-stressing of steel tube was carried out
after the curing of the specimen. Inside of the steel tube contains 8 mm
rod which act as a shear connector. It also helps to increase the
bonding between steel tube and the concrete.
3.7.6.4. Casting of Infill
The selected RPC mix details are shown in Table 3.2. The casting
was done in an EIRICH Intensive Mixer, which consist of a rotating pan
of speed 30 rpm placed at an angle of 300 to the horizontal. The inclined
rotor consists of three numbers of steel blades, which can rotate at a
speed varying from 0 to 300 rpm. The mixing was carried out in EIRICH
mixer, until a highly fluid consistency was achieved First dry mixing of
61
ingredients consisting of combination of cement, sand, silica fume was
done for 5 minutes. Subsequently 75% of water and 75% of superplasticizer (Structuro-100) with the dry mix was added and again mixed
for 3 minutes. Further the rest of water along with the super-plasticizer
was added and mixed for 5 minutes. Finally steel fibre were slowly
added and mixed for few minutes, till the desired mix consistency was
obtained. The fibre was uniformly distributed throughout the mix
volume. The mixing was continued till the required flow was achieved.
Fig 3.15 shows steel tube specimen just after the casting.