Experimental Investigation Of Concrete By Partial Replacement Of Cement By Brick Dust.

CONTENT
1. INTRODUCTION 01

2. LITERATURE REVIEW 05

3. MATERIALS USED 08

4. EXPERIMENTAL WORKS 14

5. RESULTS AND DISCUSSIONS 36

6. CONCLUSION 61

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ABSTRACT:
Concrete is a family of different materials like binding materials (cement + brick dust), Fine
aggregate, Course aggregate and water. Today construction cost is very high with using
conventional materials due to unavailability natural materials. This problem can be solved by
total replacement of concrete with different materials which is not convenient in terms of
required properties. Due to this limitation of unavailability of material whis place the vital role of
concrete we have only choice of partial replacement of concrete ingrediants by waste materials
over 3.3 billion tons of cement was consumed globally in 2010 based on survey of world coal
association and also cement production emits co2 into the atmosphere which is harmfull to the
nature. If we can partially replace the cement with the material with desirable properties then we
can save natural material and reduce the emission co2 in the atmosphere this industrial waste
dumping to the nearest site which spoils the land and atmosphere as well as it also effect
aesthetice of urban nature so use of this waste material in concrete is cost effective as well as
environment friendly way to disposal of waste.

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Durability of concrete:
Durability is outlined- capacity of concrete to defend against weathering, chemical attack and
abrasion even as keeping its preferred engineering properties. It indicates back to the duration or
life span of hindrance-free efficiency. One of a kind concretes necessitate exclusive levels of
durability relying on the exposure conditions and characteristics preferred.

Concrete remains durable if it satisfies the following:

The cement paste constitution should be intense and should be of low permeability.
Forsevere conditions, it is having entrained air to withstand freeze-thaw cycle.
It's made with graded aggregate which can be strong and inert
Components within mix include lowest amount impurities such as alkalis, Chlorides, sulfates and
silt.

Factors Affecting durability:

Cement content.
Compaction.
Curing
Cover.
Permeability.

Acid attack:

Traditional Portland cement is alkaline in nature. When the cement paste comes in contact with
the acids its components ruin down, this phenomenon is often called acid attack.
When acid attacks concrete it dissolves both hydrated and unhydrated cement compounds and
also calcareous aggregates. In among the circumstances the chemical reaction results in water
soluble calcium compounds which might be leached away. Concrete susceptibility to acid attack
rises as the pH of the acid in contact decreases from 6.5. Measure of aggression is moderate for
pH: 6.5 to 5.5, severe for pH: 5.5 to 4.5 and really extreme for pH not up to 4.5.

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Observe that the aggression of the acid attack just isn't only when you consider that of its pH
value but in addition because of the presence of CO2 in relation with the hardness of water.

1.2 Need of this study

From quantity of reports it is tested that traditional Portland cement is detrimental to atmosphere.
The procedure of producing of OPC

Increases emission green house gases

More vigor consumption for process of manufacturing of OPC
View in fiscal point.

By considering the above, it is an effect for human health and environment. As cement is a vital
material in the construction, there is a possibility of replacement of brick ash in cement based on
the study of the chemical and physical properties of the brick-kiln-ash and thus finalize the
replacement.

1.3 Objective of the study:

The goals of the present study are:

It investigates the strength and concrete efficiency at various percentage replacement of

brick-kiln-ash.
From the various percentage of replacement, finding the optimum percentage at which
desirable strength can be achieved.
The feasibility of utilizing brick-kiln-dust effectively as a substitute to cement partially is
investigated and the parameters of durability are checked.
The impact on environment by the use of brick-kiln-ash is assessed by its reuse in an
alternate way.

1.4Methodology:
Collection of brick-kiln-dust from the brick industry.
Basic tests are conducted for cement, coarse aggregate, fine aggregate, and brick dust.
Preparation of the mix design of M35.

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From the various percentage replacement of brick dust, optimum percentage replacement
will be obtained.
Casting and testing of concrete cubes, cylinders will be done.
The acid and base test for concrete with the addition of brick dust and the normal
concrete will be done and the results will be compared, durability is tested.
The strength comparison will also be done with the reference concrete.

CHAPTER: 2

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2. LITERATURE REVIEW
1) JOURNAL: Use of brick dust in concrete as mineral admixture and partial replacement of
cement.
AUTHOR: M. Kamal Uddin, Bangladesh University of engineering and technology, Dhaka-
December 3 2004.
This paper offers an overview of the physical and chemical properties of brick dust as a mineral
admixture (BDMA), which is dumped as waste from brick and tile factories in Bangladesh.
Various properties of brick dirt were studied. Experimental outcome point out that brick dust
might be used for partial replacement of cement in concrete. Concrete cubes prepared with 20%
cement replaced by way of brick dust (BDMA) shows compressive strength comparable to
concrete cubes prepared with Portland cement only. Concrete ready with 20% cement replaced
by means of BDMA additionally indicates just right resistance to chemical attack, notably the
sulfate assault. They also show better pore refinement after lengthy interval. Chemical
composition and lime reactivity strength of brick dusts have been found to be within the
variety given for excellent pozzolanic material. The pore refinement and reasonably low heat of
hydration in the presence of BDMA show that particular properties of concrete could be
expanded by way of using brick dust in combination with Portland cement
RESULTS AND CONCLUSION:
o Brick dirt as waste product from brick kilns and tile factories on hand in Bangladesh
could be used as mineral admixtures in concrete. Its use in concrete would shop as so
much as 20 percent of cement as binding fabric, whilst providing the equal strength
o Brick dirt concrete would be produced with ample droop and setting instances with
nearly the same water cementing material ratio as in natural concrete without mineral.
o Under special conditions, alternative of cement by way of brick dirt seems to expand the
strength of concrete.
o Underneath acid and sulfate attack, efficiency of cement concrete cube specimen
prepared with 20 percentage cement replaced by BDMA has been determined to be
comparable to that of the control specimen all set without BDMA.
o In mass concrete, use of brick dirt as mineral admixture would lower the heat of
hydration, which would help to control the development of secondary stresses within the
buildings.

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o The brick dust mineral admixture has a reddish color, which could be aesthetically extra
high-quality.

2) JOURNAL: A Study on Low Performance Concrete using Mineral Admixtures (Brick Kiln
Dust and Silica Fume)

AUTHOR: Rajesh Kumar Bharti, Mr. R.D. Patel, IJSRD -International Journal for Scientific
Research & Development, Vol. 2, Issue 10, 2014

The mix proportions must be prepared in the sort of means that the coarse aggregate participation
in quantity should be diminished and the great aggregate in the powder form is to be expanded.
In present paper, cement is a permanent agent, the alternative of cement with the aid of Silica
Fume in percentages specifically (0% 5%, 10% and 15%) and Brick Kiln dust (BKD) in
percentages particularly (0%, 5%, 10% and15%) with W/C ratio of 0.50 the study on fresh
properties of LPC; Compressive strength and split tensile strength of LPC had been made. It used
to be found that the alternativeofcement by 15% silica fume (FA) and 10% Brick kiln dirt
(BKD) gives highest compressive strength and split tensile strength correspondingly. Dumping
of brick dust and other throw away brick particles. flakes and many others, now not
handiestinhabit land but in addition generate ecological problems. The troubles might be
diminished to anenormous extent byutilizingof these throw away materials in cement concrete.
The reasons for utilizing brick dust comprise least expensive achieve and beneficial modification
of particular properties of fresh and hardened concrete factors. This data offers an outline of the
physical and chemical properties of brick dust as a mineral admixture (BDMA), which is
discarded as waste from brick and tile factories in Bangladesh. Diverse properties of brick dust
have been considered. Experimental outcome specify that brick dust could be used for fractional
substitute of cement in concrete. Concrete cubes primed with 20% cement replaced by means of
brick dirt (BDMA) show compressive strength similar to concrete cubes prepared with Portland
cement handiest. Concrete all set with 20% cement replaced through BDMA in addition shows
good resistance to chemical attack, peculiarly the sulfate attack .They in addition demonstrate
improved pore refinement after lengthy interval. Chemical composition and lime reactivity
strength of brick dusts have been observed to be inside the range given for good pozzolonic
material. The pore refinement and fairly low heat of hydration in the existence of BDMA show
that specific properties of concrete would be extended by using brick dirt in fuse with Portland
cement. India is the 2nd greatest manufacturer of clay fired bricks, accounting for additional 10%

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of worldwide fabrication .Indias brick sector is characterized by average firing applied sciences;
ecological pollution; reliance on manual work and low automation rate; dominance of small-
scale brick kilns with confined financial, technical and supervisory ability; governance of
single raw material.

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CHAPTER: 3

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3. MATERIALS USED:

3.1 Cement
Cement is a binder, a substance used in construction that sets and hardens and may bind other
materials collectively. Cement is described as a material with adhesive and cohesive properties
which make it equipped of bonding mineral fragments into a compacted entire. It embraces huge
sort of cementing materials. For construction purposes the meaning of the term cement is
restricted to the bonding material used with stones, sand, bricks, constructing blocks, and so on.
The prime constituents of this form of cement compounds of lime, so that in building and civil
engineering we're linked with calcareous cement. The cements have property of setting in under
water by means of chemical response releasing heat of hydration. So called as hydraulic cement.
Hydraulic cement consists normally of silicates and aluminates of lime, and may also be
classified generally as typical cements, Portland cements, and high alumina cements.

Fig-1: Cement

3.2 Aggregates
Aggregates are vital constituents of the concrete. They are used chiefly for intention to provide
bulk for concrete, lessen shrinkage and achieve economy. To boost the density of the resultant
mix, the aggregate is chronically used in two or more sizes. The meager fact that the aggregates
take up 70-80% of the volume of concrete, and hence its impact on a variety of characteristics
and properties of concrete is unquestionably considerable. The aggregate ought to be of
appropriate shape(rounded or approximately cubical), clean, rigid, tough and well graded. It must

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possess chemical stability and in numerous cases show abrasion resistance and resistance to
freezing and thawing.

Aggregates are widely categorized into two companies established on their dimension:

3.2.1 Fine Aggregates: It's the aggregate the majority of which pass 4.75 mm IS sieve and
involves most effective coarse as is approved by requirement. In line with supply fine aggregate
is also categorized as:

Natural Sand
Crushed Stone Sand
Crushed Gravel Sand

Fig-2:-Fine aggregate

3.2.2 Coarse Aggregates:

It is the aggregate the majority of which is retained lying on 4.75 mm IS sieve and contain
simplest so much finer fabric as is accredited through requirement. Consistent with supply,
coarse aggregate is also described as:

Uncrushed Gravel or Stone

Crushed Gravel or Stone
Partially crushed Gravel or Stone

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Fig-3:-Coarse aggregate

3.3 Water:
Water mixed with cementitious material form a cement paste with aid of approach of hydration.
The cement paste glues the aggregate together, fills voids inside it, and makes it flow extra
freely.

Lower w/c ratio yields a much better, extra durable concrete, while more water offers a free-
flowing concrete with a greater slump. Impure water used to prepare the concrete mix can cause
issues when setting or in inflicting premature failure of the structure.

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3.4 Brick Dust

Mainly, brick contains the following:

1. Silica (sand) 50% to 60% by weight

2. Alumina (clay) 20% to 30% by weight
3. Lime 2 to 5% by weight
4. Iron oxide 7% by weight
5. Magnesia less than 1% by weight

In India, brick manufacturing is usually a manual system. The most long-established variety of
brick kiln in use is the Bull's Trench Kiln (BTK) where an oval or circular trench is dug; a tall
exhaust chimney is developed within the core. Half or more of the ditch is full of "green"
(unfired) bricks that are stacked in an open lattice sample to allow airflow. The lattice is capped
with a roofing layer of completed brick. Within the core, the brick employees create a firing zone
by way of fuel dropping (coal, timber, oil, particles) in the course of entry holes in the roof on
top of the ditch.

One of the crucial most important by-products (or rather waste) generated for the period of the
making of clay bricks is brick ash which is gathered in the core of the kiln.

Fig-4:- brick ash

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CHAPTER: 4

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4. EXPERIMENTAL WORKS
As recounted earlier, the target of this paper is to study the physical and mechanical changes and
also durability factors in concrete by means of replacing the cement with brick ash. The
information about the raw substances used, the methodology adopted and the results are
mentioned beneath.

4.1 Methodology
Collection of brick ash and other ingredients required for the concrete mix.

Basic tests are conducted for cement, coarse aggregate, fine aggregate and brick ash.
Preparation of the mix design for M35 grade.
Casting of the cubes and cylinders by varying the percentage of brick ashand testing of
the same will be done.
From the various percentage replacement of brick ash, optimum percentage replacement
will be obtained.
The acid and base test for concrete with the varying percentage replacement of brick ash
and the normal concrete will be done and the results will be compared, durability is
tested.
The strength comparison will also be done with the reference concrete.

4.1.1 Procuring of materials

Brick dust obtained from Kolar,Bidar, Karnataka.
Fine and coarse aggregate from Bidar, Karnataka.
Cement bags from nearby storage units of Ultratech Cement.

4.1.2 TESTS OF MATERIALS (Conduction of basic tests for the procured

materials):
4.1.2.1 CEMENT
4.1.2.1.1 SPECIFIC GRAVITY
Specific gravity is the ratio between the weight of a given volume of cement and weight of an
equal volume of water.

Apparatus: Specific gravity bottle, balance capable of weighing accurately up to 0.1 Gms.

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TEST PROCEDURE

1. Dry the specific gravity bottle, evaluate it with its stopper (W1).
2. Fill the sample of cement till half of the flask (about 50 Gms) and consider with its stopper
(W2).
3. Add kerosene to flask until it's about half of full and mix completely with a glass rod to take
away entrapped air.
4. Proceed stirring and fill extra kerosene until it's full till the graduated mark. Dry the external
surface and weigh (W3).
5. Entrapped air is also removed with the aid of vacuum pump, if available. Empty the flask,
restock with kerosene until the graduated mark.
6. Wipe external surface and weigh (W4).

CALCULATION
21
Specific gravity = (21}(34)0.79

4.1.2.1.2 FINENESS TEST

Fineness of cement is calculated by sieving it on standard sieve. The quantity of cement of
which the grain sizes are bigger than the specified mesh size is thus determined.

APPARATUS: Glass rod, stoppered jar, pan, lid, 90 micron sieve

PROCEDURE

Stir up the sample of cement to be tested for two minutes in a stoppered jar to diffuse
agglomerates. Stir the consequential powder gently making use of a smooth dry rod in an
attempt to distribute the fines throughout the cement.
Fasten a pan beneath the sieve to accumulate the cement passing the sieve.
Weigh roughly 10 g of cement to the nearest 0.01 g and place it on the sieve. Match the
lid over the sieve.
Disturb the sieve by using swirling, planetary and linear movement unless no extra fine
material passes through it.
Cast off and weigh the residue. Categorical its mass as a percentage (R1) of the quantity
first placed in the sieve.
Repeat the steps three to five with a contemporary sample to acquire R2..

CALCULATION

Compute the residue of cement R as the mean of R1 & R2 (or R1, R2 & R3) in %, articulated to
the nearest 0.1%.

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PRECAUTION

Prior to sieving, air set lumps of cement should be broken down

Sieving is ought to be done by rotating the sieve and not by translation.

4.1.2.1.3 STANDARD CONSISTENCY TEST

Standard consistency of cement paste is the consistency which will allow a Vicat plunger
having 10 mm diameter and 50 mm length to penetrate to a depth of 33-35 mm from top
of the mould.

MEASURING INSTRUMENTS: Vicat apparatus, balance, measuring cylinder

Fig-5:-Vicats apparatus

Method

1. Get four hundred g of cement and position it in the enameled tray.

2. Combine about 25% water by weight of dry cement fully to get a cement paste. Total time
taken to receive entirely combined water cement paste i.e. Gauging time will have to no longer
be more than 3 to 5 minutes.
3. Fill up the Vicat mould, resting upon a glass plate, with this cement paste.
4. Subsequent to filling up the mould entirely, smoothen the surface of the paste, making it level
with prime of the mould.

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5. Place the entire assembly (i.e. Mould + cement paste + glass plate) below the rod bearing
plunger.
6. Scale down the plunger gently with the intention to contact the surface of the experiment
block and quickly liberate the plunger enabling it to sink into the paste.
7. Measure the depth of penetration and document it.
8. Prepare trial pastes with various percentages of water content and follow the steps (2 to 7) as
described above, till the depth of penetration turns into 33 to 35 mm.

CALCULATION

Calculate percent of water (P) by using weight of dry cement essential to organize cement paste
of standard consistency through following the equation, and express it to the first position of
decimal.

Where,
W=Quantity of water added
C=Quantity of cement used

PRECAUTIONS

Gauging time is ought to be firmly observed

Room temperature must be excellently maintained as per experiment requirement.
All apparatus used ought to be tidy.
The experiment should be carried out far from vibrations and other disturbances.

TECHNICAL DISCUSSIONS

This experiment helps to find out water content for different checks like initial and final
setting time, soundness & compressive strength.
Consistency refers to the relative mobility of a freshly mixed cement paste or mortar or
its capability to flow. For a mortar the standard consistency is calculated by way of flow
table test.
Recurrently the normal consistency for OPC degrees from 26 to 33%.

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4.1.2.1.4 INITIAL SETTING TIME AND FINAL SETTING TIME TEST

Initial setting time is that time interval between the time water is added to cement and time at
which needle fails to penetrate the cement paste, placed in the Vicats mould 5 mm to 7 mm
from the flipside of the mould.

Final setting time is that time period between the time water is added to cement and the time at
which 1 mm needle makes an impression on the paste within the mould but 5 mm attachment
does not make any affect.

It is fundamental to estimate the initial setting time and final setting time as they give a notion of
the time required for the cement to initiate hardening and likewise start gaining strength.

APPARATUS:

Vicat apparatus- Should be as per IS: 5513

Balance- range of 1000g to1g
Measuring cylinder capacity of 100ml to 1ml
Stopwatch- range of 30 min with least count of 0.2 sec
Glass plate
Enamel tray
Trowel

PROCEDURE

(A)TEST BLOCK PREPARATION

Prior to initiating setting time test, the consistency test should be done to find the water
essential to provide the paste normal consistency (P).
Take 400 g of cement and prepare an efficient cement paste with 0.85P of water by
weight of cement.
Gauge time is kept between 3 to 5 minutes. Begin the stop watch at the moment when the
water is added to the cement. This time is recorded (t1).
Fill up the Vicat mould, resting on a glass plate, with the cement paste gauged as above.
Fill up the mould completely and level off the surface of the paste make it even with the
top of the mould. The cement block thus prepared is called test block.

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(B)INITIAL SETTING TIME

Place the test block restricted within the mould and resting on the non-porous plate, under
the rod which is bearing the needle.
Lower the needle gently until it comes in contact with the surface of test block and rapid
liberate, allow it to penetrate into the test block.
Within the starting the needle entirely pierces the test block. Repeat this approach i.e.
swiftly releasing the needle after each 2 minutes till the needle fails to penetrate the block
for about 5 mm measured from the backside of the mould. Note this time (t2).

(C)FINAL SETTING TIME

To determine the final setting time, substitute the needle of the Vicats apparatus by the
needle having annular attachment.
The cement is considered to be finally set when upon applying the final setting needle
smoothly to the surface of the test block; the needle makes an impression, whereas the
attachment fails to do so. Document this time as t3

CALCULATION

Initial setting time = t2-t1

Final setting time = t3-t1,

Where,
t1 = Time at which water is first added to cement.
t2 = Time when needle fails to penetrate 5 mm to 7 mm from bottom of the mold.
t3 = Time when the needle makes an impression however the attachment fail to do so.

PRECAUTIONS

Let go the initial and final setting time needles smoothly.

The test should be performed away from vibration and other disturbances.
Needle should be cleaned every time it is used.
Position of the mould ought to be shifted to some extent after every penetration to avoid
penetration at the same place.
Test should be performed at specified environmental conditions.

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4.1.2.2 TESTS ON COARSE AGGREGATES:

4.1.2.2.1 SPECIFIC GRAVITY

APPARATUS

A balance or scale of capacity not lower than 3 kg, legible and accurate to 0.5 g and of
any such variety and form as to allow the basket containing the sample to be suspended
from the beam and then weighed in water.
A good ventilated oven thermostatically managed to maintain a temperature of 100C-
110C
A wire basket of not greater than 6.3 mm mesh or a perforated container of suitable size.
A stout water tight container of handy size.
Two dry tender absorbent cloths each no longer less than 7545 cm
A shallow tray AREA not less than 650 cm2
An air tight container of ability alike to that of the basket.

PROCEDURE

Take 2 kg of aggregate and wash the sample carefully to get rid of finer particle and dust.
Situate the sample in a wire basket and submerge it in distilled water at a temperature
between 22C and 32C with a cover of at least 5 cm of water exceeding the top of the
basket.
Eliminate the entrapped air by stimulating the basket containing the sample 25 mm above
the base of the tank and allow it to fall, care should be taken to see that the sample is
entirely engrossed in water during the operation.
Weigh the sample which is in the water at a temperature of 22C-32C (W1).
Take away the basket and aggregate from water and permit it to drain for a few minutes.
Pour out the aggregate from the basket to a shallow tray.
Submerge the empty basket in water shove 25 times and then take the weight in water
(W2).
Position the aggregates in oven at a temperature of 100C to 110C for 24+- 0.5 hours.
Take it out from the oven and cool it and find the weight. (W3)

CALCULATIONS

Apparent Specific Gravity = (Weight of a substance/ Weight of an equal volume of water)

3
= 3(12)

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4.1.2.2.2 WATER ABSORPTION

This test helps us to examine the water absorption of coarse aggregates as per IS: 2386 (section
III) 1963. For this experiment a sample not a lesser amount 2000g should be taken.

APPARATUS:

Wire basket with wire hangers to suspend it from the balance, Air-tight container of a capacity
alike to that of the basket and Oven, Dry soft absorbent cloth.

PROCEDURE:

The sample must be utterly washed to do away with finer particles and dust, drained and
then positioned within the wire basket and engrossed in distilled water at a temperature
between 22 and 32C.
Subsequent to immersion, the entrapped air will have to be eliminated by lifting up the
basket and letting it to drop 25 times in 25 seconds. The basket and pattern must remain
immersed for a period of 24 + hours afterwards.
The basket and aggregates must then be taken out from the water, permitted to drain for a
few minutes, after which the aggregates must be gently emptied from the basket on to one
of the dry garments and gently surface-dried with the material, transferring it to a 2nd dry
cloth when the primary would remove off no additional moisture. The aggregates should
be spread out on the 2nd fabric and exposed to the surroundings faraway from direct
sunlight until it seems to be fully surface-dry. The aggregates must be weighed as A.
The aggregates will have to then be positioned in an oven at a temperature of 100C to
110C for 24hrs. It must then be taken out from the oven, cooled and weighed as B.

FORMULA = 100%.

4.1.2.3.3. BULK DENSITY

APPARATUS

No Name Capacity
1 Balance Sensitive up to 0.5% of the weight of the
material
2 Cylindrical metallic measure 3 lt
3 Tamping rod 16mm dia, length 60 cm

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A. PROCEDURE FOR COMPACTED BULK DENSITY

Measure the quantity of the cylindrical metal measure by means of pouring water into the
metallic measure and document the volume in m3 V.
Fill up the cylindrical metallic measure about one-third full with completely mixed
aggregates and tamp it 25 times with the help of tamping bar.
Add an extra layer of 1/3rd volume of aggregate within the metallic measure and give an
extra 25 strokes by tamping bar.
Finally fill the aggregate within the metallic measure till over-flowing and tamp it 25
times.
Put off the additional aggregate using the tamping rod as a straightedge.
Assess the weight of the aggregate in the measure and record that weight as W in kg.

CALCULATION FOR COMPACTED BULK DENSITY

Compacted unit weight or bulk density =
Where,
W = Weight of compacted aggregate in cylindrical metallic measure in kg
V = Volume of cylindrical metal measure in liter.

CALCULATION OF VOIDS

The percentage of voids is calculated through the following:

Percentage of voids = 100

Where,
G = Specific gravity of the aggregate
= Bulk density in kg/ m3

B. PROCEDURE FOR LOOSE BULK DENSITY

Measure the volume of the cylindrical metallic measure via pouring water into the metal
measure and report the volume as V in m3.
Fill the cylindrical measure to brimful by the use of a shovel or scoop, the aggregate
being discharged from a height now not exceeding 5 cm above the top of the measure
Level the topmost surface of the aggregate within the metallic measure, with a
straightedge or tamping bar.
Examine the weight of the aggregate within the measure and file the weight as W in kg

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CALCULATION FOR LOOSE BULK DENSITY

Loose unit weight or bulk density =
Where,
W = Weight of loose aggregate in cylindrical metallic measure in kg
V = Volume of cylindrical metallic measure as m3

CALCULATION OF VOIDS

The percentage of voids is calculated as follows

Percentage of voids = 100

Where,
G = Specific gravity of the aggregate
= Bulk density in kg/liter

RESULT
The bulk density is measured in kg/m^3 to the nearest of 0.01 kg

4.1.2.3 TESTS ON FINE AGGREGATES:

4.1.2.3.1 SPECIFIC GRAVITY
APPARATUS

1. A balance of potential no less up to 3kg , readable and accurate to 0.5 gm and of this kind of
variety as to allow the weighing of the vessel containing the aggregate and water .

2. A well ventilated oven to hold a temperature of a 100C to a 110C

3. Pycnometer of about 1 liter potential having a steel conical screw top with a 6mm hole at its
apex. The screw top might be water tight.

4. A system supplying a current warm air.

5. A tray of area now not lesser to 32cm.

6. An air tight container huge enough to take the sample.

7. Filter papers and funnel

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PROCEDURE

The weight of a dry and clean pycnometer with its cover as W1.
Take with reference to 500g (or one third volume of pycnometer) of sample and consign
it in the pycnometer and weigh with its cap as W2.
Pour distilled water unto it till it is full. Get rid of the entrapped air by turning the
pycnometer unto its side, the hole at the apex of the cone being enclosed with a finger.
Wipe up the outer surface of pycnometer and weigh it as W3.
reassign the filling of the pycnometer into a tray, care should be taken to make certain
that all the aggregate is transferred
Stock up the pycnometer with distilled water to the same level and weigh it as W4.

CALCULATION
21
Apparent specific gravity =(21)(34)

4.1.2.3.2 MOISTURE CONTENT

APPARATUS:

Balance - A balance or scale of capacity no longer lower than three kg, readable and
precise to 0.5 g, and of this type of sort as to permit the weighing of the vessel containing
the aggregate and water.
Oven - A well ventilated oven, thermostatically controlled, to conserve a temperature of
100 to 110C.
Vessel - Any type of vessel equipped of maintaining 0.5 to 1 kg of material as much as
10 mm in measurement and able of being stuffed with water to a constant volume with an
precision of 5 ml.

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METHOD:

The clean sample must be immersed in distilled water at a temperature between 22 and
32C. The entrapped air ought to be eliminated. Sample should stay immersed for a
period of 24 + hours.
The aggregates will have to be gently emptied from the vessel on to probably the driest
piece of cloth and gently surface-dried with the cloth, transferring it to a second dry cloth
when the primary would do away with no extra moisture. The aggregates should be
spread on the second cloth and uncovered to the atmosphere far from direct daylight till it
seems to be entirely surface-dry. The aggregates must be weighed as Weight A.
The aggregates will have to then be placed in an oven at a temperature of 100 to 110C
for 24hrs. It should then be taken out from the oven, cooled and weighed B

FORMULA =. 100%

4.1.2.3.3. BULK DENSITY

APPARATUS

1. Balance Sensitive to 0.5% of weight of material

2. Cylindrical metal measure of 3 liter
3. Tamping rod of 16 mm dia. and 60 cm long

A. PROCEDURE FOR COMPACTED BULK DENSITY

Measure the volume of the cylindrical metal measure through pouring water unto the
metallic measure and file the quantity V in m3.
Fill the cylindrical metallic measure about one- third full with entirely mixed aggregate
and tamp it 25 times making use of tamping bar.
Add one more layer of 1/3 quantity of aggregate in the metallic measure and give an
extra 25 strokes of tamping bar.
Finally fill aggregate within the metallic measure to the brim and tamp it 25 instances.
Cast off the excess aggregate by means of the tamping rod as a straightedge.
Assess the weight of the aggregate in the measure and report that weight as W in kg.

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CALCULATION FOR COMPACTED BULK DENSITY

Compacted unit weight or bulk density =
Where,
W = Weight of compacted aggregate in cylindrical metallic measure in kg
V = Volume of cylindrical metallic measure in liter

CALCULATION OF VOIDS

The percentage of voids is calculated through the following:

Percentage of voids = 100

Where,
G = Specific gravity of the aggregate
= Bulk density in kg/ m3

B. PROCEDURE FOR LOOSE BULK DENSITY

Measure the volume of the cylindrical metallic measure through pouring water into the metallic
measure and document the quantity as V in m3.
Fill the cylindrical measure to the brim by means of a shovel or scoop, the aggregate being
discharged from a height not exceeding 5 cm above the top of the measure
Degree the top surface of the aggregate within the metallic measure, with a straightedge or
tamping bar.
Check the weight of the aggregate in the measure and report the weight asW in kg.

CALCULATION FOR LOOSE BULK DENSITY

Loose unit weight or bulk density =
Where,
W = Weight of loose aggregate in cylindrical metallic measure in kg
V = Volume of cylindrical metallic measure as m3

CALCULATION OF VOIDS

The percentage of voids is calculated as follows

Percentage of voids = 100

Where,
G = Specific gravity of the aggregate
= Bulk density in kg/liter

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RESULT
The bulk density is recorded in kg/m3 to the nearest 0.01 kg

4.1.2.1. SPECIFIC GRAVITY FOR CEMENT

1. Weight of empty density bottle (w1) = 77.6grms

2. Weight of empty density bottle + water (w2) = 176.8grms
3. Weight of empty density bottle + kerosene (w3) = 156.7grms
4. Cement + Density bottle (w4) = 96.8grms
5. Cement+ Density bottle + kerosene (w5) = 171grms
31 156.777.6
Specific gravity of kerosene =21= 176.877.6

Specific gravity of kerosene = 0.8

Specific gravity of cement

41
= (31)(54) 0.8

96.877.6
= (156.777.6)(17196.8) 0.8

Specific gravity of cement = 3.15

4.1.2.2. TEST FOR SPECIFIC GRAVITY OF FINE AGGREGATE AND

MOISTURE CONTENT

1. Mass of emptypycnometer (M1) = 659.5grms

2. Mass of pycnometer + given sample (M2) = 1461.98grms
3. Mass of pycnometer+ given sample + water (M3) = 2053grms
4. Mass of pycnometer + water (m4) = 1548.4grms
21 1461.98659.5
Specific gravity = (41)(32)=(1548.4659.5)(20531461.98)

Specific gravity = 2.605

21(1) (1461.98659.5)(2.6051)
Percentage of water absorption = (34)
= (20531548.4)2.605 *100

Percentage of water absorption = 1.23%

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4.1.2.3 SPECIFIC GRAVITY OF COARSE AGGREGATE AND WATER

ABSORPTION TEST

1. Weight of the surface dry sample (W1) = 3000grms

2. Weight of empty wire basket in water (W2) = 1040.05grms
3. Weight of wire basket + sample in water (W3) = 3000grms
4. Weight of dried sample (w4) = 2971.05grms
1 3000
Specific gravity = =
1(32) 3000(30001040.05)

Specific gravity = 2.884

14 30002971.05
Water absorption = *100== 100
4 2971.05

Water absorption = 0.97%

4.1.3 PREPARATION OF MIX DESIGN FOR M35 GRADE CONCRETE

4.1.3.1 Stipulations for proportioning

1. Type of the cement used: OPC 53 grade conforming to IS 8112

2. Maximum nominal aggregate size: 20 mm
3. Minimum cement content: 320 kg/m3
4. Maximum water-cement ratio: 0.45
5. Workability: 100 (slump)
6. Exposure conditions: Normal
7. Method of placing concrete:Hand placed
8. Degree of supervision: Good
9. Type of aggregate: Crushed angular aggregate
10. Type of Chemical admixture: Superplasticizer

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4.1.3.2 Test data for materials

no. Physical properties Coarse Fine aggregate
aggregate

1 Specific gravity 2.88 2.605

2 Water absorption 0.97% 1.23%

3 Sieve analysis Zone I Zone II

Specific gravity of cement=3.15

4.1.3.3 Target strength for mix proportioning

fck = fck + 1.65 s
Where,
f'ck = target average compressive strength at 28 days,
fck = characteristic compressive strength at 28 days, and
s = standard deviation.
From Table I of IS 10262: 2009,
Standard deviation, s =5 N/mm2
Therefore,

Target strength = 35 + 1.65 x 5 = 43.25 N/mm2

4.1.3.4 Selection of water-cement ratio

From the graph, page 8 of IS 10262: 1982
Water-cement ratio as 0.45
0.45 < 0.40, hence OK.

4.1.3.5 Selection of water content

From Table 2,
Maximum water content =186 liter (for 25 to 50 mm slump range) for 20 mm aggregate.
As super plasticizer is used, the water content is decreased by 15%.
Therefore,
Water content = 0.85186 = 158.1 160 liters.
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4.1.3.6 Calculation of cement content

Water-cement ratio = 0.45

Cement content =160/.45 = 355.55 kg/m3 360 kg/m3
From Table 5 of IS 456, minimum cement content for 'moderate' exposure = 240 kg/m3
360 kg/m3 > 240 kg/m3, hence, O.K.

4.1.3.7 Volume of coarse aggregate and fine aggregate

From Table 3 of IS 10262: 1982, for 20 mm aggregate and water-cement ration of 0.5, volume of
coarse aggregate is 0.46.
For water-cement ratio of 0.45, volume of coarse aggregate is 0.46.
(As the water-cement ratio is lower by 0.10. the proportion of volume of coarse aggregate is
increased by 0.02 (at the rate of -/+ 0.01 for every 0.05 change in water-cement ratio).

Volume of fine aggregate=1-.62=0.38

4.1.3.8 Mix calculations

a) Volume of concrete = 1 m^3

1
b) Volume of cement = 1000

360 1
= 3.14 1000

= 0.114m3

1
c) Volume of water = 1000

160 1
= 1000
1

= 0.160 m3

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d) Volume of chemical admixture takes as 0.5% by mass of cement

1
= 1000

1.9 1
=1.45 1000

=0.00165m3

e) Volume of all in aggregate = [a-(b+c+d)]

= [1-(0.114+0.16+0.00165)]

= 0.724 m3

f) Mass of fine aggregate

= e Volume of fine aggregate Specific gravity of fine aggregate 1000

= 0.724 0.38 2.605 1000

= 716.688 717 kg/m3

g) Mass of coarse aggregate

= e Volume of coarse aggregate Specific gravity of coarse aggregate 1000

= 0.724 0.46 2.884 1000

= 960.487 960 kg/m3

4.1.3.8 Mix proportion

Cement = 360 kg/m3

Water = 160 kg/m3

Fine aggregate = 717 kg/m3

Coarse aggregate = 960 kg/m3

Admixture = 1.9 kg/m3

Water-cement ratio = 0.35

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4.1.3.9 Mix ratio

Cement Fine aggregate Coarse aggregate

1 2 2.6

4.2 Steps to be followed to cast the samples

1. Preparation of moulds: The moulds (made of cast iron plates) should be tightened and
oiled well in advance before pouring the concrete into the moulds.

2. Mixing of materials:The required quantity of materials as calculated in the mix design is

mixed according to the mix proportion arrived in the mixer.

Fig-6:- Mixing of materials

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3. Placing and compacting of the concrete: The mixed concrete is poured into the
moulds in 3 subsequent layer, every layer is tamped 25 times to attain good compaction.

Fig-7:- Placing

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4. Demoulding and curing:The compacted samples are allowed to set for 24 hours after
which the cubes are detached frommoulds and put into water foressential amount of curing.

Fig-8:- Demoulding

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CHAPTER: 5

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5. RESULTS AND DISCUSSIONS

5.1 Properties of cement
The following table shows the physical characteristics of cement used:

Sl no. Properties Results

1 Specific gravity 3.15

2 Fineness 3%

3 Normal consistency 31%

5.2 Properties of coarse aggregate

The following table shows the physical characteristics of coarse aggregate used:

Sl no. Properties Values

1 Specific gravity 2.884

2 Water absorption 0.97%

3 Bulk density (compacted) 1760 kg/m3

5.3 Properties of fine aggregate

The following table shows the physical characteristics of fine aggregate used:

Sl no. Properties Results

1 Specific gravity 2.605

2 Water absorption 1.23%

3 Bulk density (compacted) 1653 kg/m3

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5.4 Sieve analysis

The following table shows the gradation of the aggregates used:

Coarse aggregate Fine aggregate

Sieve size in % passing Sieve size in mm %

mm passing

12.50 99.10 4.75 99.93

10.00 87.79 2.36 95.02

6.35 35.31 1.18 78.48

4.75 16.57 0.60 49.48

- - 0.30 7.28

- - 0.15 0.07
Fineness modulus = 6.61 Fineness modulus = 3.31

5.5 Test results for conventional M35 cubes

The following table shows the various strength parameters of conventional M35 concrete (i.e.
0% replacement) samples.

7 days results Strength in N/mm2

Compressive strength 30.91 30.8 30.4

28 days results Strength in N/mm2

Compressive strength 41.2 41.1 40.8

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5.6 Test results for cubes

Fig-10:- Cubes for testing

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Fig-11:- Cubes weighed before testing

COMPRESSIVE STRENGTH (7 days)

% Replacement Sample 1 Sample 2 Sample 3

Normal Concrete 30.91 30.8 30.4
10 28.8 28.6 28.4
15 27.6 27.5 27.8
20 25.6 24.71 23
25 22.27 22.01 22.3
30 20.1 20.52 20.3

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COMPRESSIVE STRENGTH (7 DAYS)

30.91 30.8 30.4

28.8
28.6
28.4

27.8
27.6
27.5

24.71
25.6

22.27
22.01
22.3

20.52
23

20.3
20.1
10 15 20 25 30

COMPRESSIVE STRENGTH (28 days)

% Replacement Sample 1 Sample 2 Sample 3
Normal Concrete 41.2 41.1 40.8
10 40.1 35.6 38.1
15 38.8 38.6 38.8
20 35.4 34.8 36.2
25 32.1 33.1 32.5
30 28.6 29.8 30.2

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COMPRESSIVE STRENGTH (28 DAYS)

41.2 41.1 40.8
40.1

38.8

38.8
38.6

38.6
38.1

36.2
35.4
34.8

33.1
32.5
32.1

30.2
29.8
28.6
10 15 20 25 30

5.6.1 16% replacement of cement with brick ash.

Days of testing Compressive Strength in N/mm2

Sample 1 2 3

7 27.8 28 28.2

28 39.6 39.5 39.4

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45
Compression strength N/mm2
40
7 and 28 days compressive strength
35
30
25
20 normal concrete
15 16% replacement
10
5
27.839.6 28 39.5 28.239.4
0
cube1 cube2 cube3
Number of cubes

7 and 28 days compressive strength

45
Compression strength N/mm2

40 39.6 39.5 39.4

35
30
27.8 28 27.2
25 normal concrete
20 16% replacement
15
10
5
0
0 1 2 3 4
Number of cubes

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Fig-12:- Compression testing

5.6.2 17% replacement of cement with brick ash

Days of testing Compressive Strength in N/mm2

Sample 1 2 3

7 27.2 27.6 27.5

28 40 40.2 40.1

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45
7 and 28 days compressive strength
40
Compression strength N/mm2

35

30

25

20 normal concrete
17% replacement
15

10

5
27.2 40 27.6 40.2 27.5 40.1
0
cube1 cube2 cube3
Number of cubes

45
7 and 28 days compressive strength
40 40 40.2 40.1
Compression strength N/mm2

35

30
27.2 27.6 27.5
25

20 normal concrete
17% replacement
15

10

0
0 0.5 1 1.5 2 2.5 3 3.5
Number of cubes

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5.6.3 18% replacement of cement with brick ash

Days of testing Compressive Strength in N/mm2

Sample 1 2 3

7 26.4 27.3 26.2

28 37.4 37.6 37.4

40
28 days compressive strength
35
Compression strength N/mm2

30

25

20
normal concrete
15
18% replacement
10

5
26.4 37.4 27.3 37.6 26.2 37.4
0
cube1 cube2 cube3
Number of cubes

40
7 and 28 days compressive strength
Compression strength N/mm2

37.4 37.6 37.4

35
30
26.4 27.3 26.2
25
20 normal concrete

15 18% replacement
10
5
0
0 1 2 3 4
Number of cubes

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5.6.4 19% replacement of cement with brick ash

Days of testing Compressive Strength in N/mm2

Sample 1 2 3

7 25.1 24.94 25.51

28 36.3 37.1 36.8

40
7 and 28 days compressive strength
Compression strength N/mm2

35
30
25
20
normal concrete
15
19% replacement
10
5
25.1 36.3 24.9437.1 25.5136.8
0
cube1 cube2 cube3
Number of cubes

7 and 28 days compressive strength

40
36.3 37.1 36.8
Compression strength N/mm2

35
30
25 25.1 24.94 25.51
normal concrete
20
19% replacement
15
10
5
0
0 1 2 3 4
Number of cubes

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5.9 TESTS ON DURABILITY OF CONCRETE:

The test for durability is done by subjecting the cubes for the chemical tests. This is done in
order to evaluate the undesirable effect of the chemicals which may cause deterioration to the
concrete. The deterioration may be due to the different chemicals present in the nature.

Method:

After the normal water curing is done these cubes are subjected to acid and base curing for 28
days. The cubes are tested for its strength and it is compared.

Acid attack:

This is done for the concrete cubes to check the deterioration caused by the acids. This study is
particularly useful in the areas where there will be acid rains.

This test involves the dilution of hydrochloric acid which is 10% of the total quantity of water
taken for the curing purpose. After the required period of curing, the strength is checked and
comparison is done.

Base attack:

This test is done in the marine regions to check the deterioration caused by the bases on the
concrete structure.

Sodium sulfate is used for this test. It is taken 15% by weight of the quantitywater used for the
curing purpose. Curing is done for the required period and the strength is calculated.

Fig-13:-Cubes after 28 days of acid and base curing

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Fig-14:- Weighing of the cubes which is cured in acid before testing

Fig-15:- Weighing of cubes cured in base before testing

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5.9.1 ACID TEST:

5.9.1.1 % replacement of cement with brick ash

% Replacement Compressive strength for 28days in

of cement with 28N/mm2
brick ash
Sample 1 Sample 2 Sample 3

16 24.44 26.22 26.66

17 24.44 24.00 22.22

18 22.66 20.00 22.22

19 18.22 15.11 16.88

16% replacement:

35
28 days compressive strength for acid test
30
compressive strength N/mm2

25

20

16% replacement(water)
15
16% replacement (acid)
10

5
29.2424.44 29.626.22 27.5126.66
0
cube1 cube2 cube3
Number of cubes

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35
28 days compressive strength for acid test
30 29.24 29.6
compressive strength N/mm2

27.51
26.66
26.22
25 24.44

20

16% replacement
15
16% replacement(acid)
10

0
0 1 2 3 4
Number of cubes

17% replacement:

30
28 days compressive strength for acid test
25
compressive strength N/mm2

20

15
17% replacement(water)
17% replacement(acid)
10

27.0224.44 27.98 24 26.2222.22

0
cube1 cube2 cube3
Number of cubes

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30
28 days compressive
27.98 strength for acid test
27.02
26.22
25 24.44 24
compressive strength N/mm2

22.22
20

15
17% replacement
17% replacement(acid)
10

0
0 1 2 3 4
Number of cubes

18% replacement

30
28 days compressive strength for acid test
25
compressive strength N/mm2

20

15
18% replacement
18% replacement(acid)
10

25.3322.66 24 20 25.5122.22
0
cube1 cube2 cube3
Number of cubes

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30
28 days compressive strength for acid test
25 25.33 25.51
24
compressive strength N/mm2

22.66 22.22
20 20

15
18% replacement
18% replacement(acid)
10

0
0 1 2 3 4
Number of cubes

19% replacement

30
28 days compressive strength for acid test
25
compressive strength N/mm2

20

15
19% replacement
19% replacement(acid)
10

25.0418.22 23.1115.11 23.7816.88

0
cube1 cube2 cube3
Number of cubes

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30
28 days compressive strength for acid test
25 25.04
compressive strength N/mm2

23.11 23.78

20
18.22
16.88
15 15.11
19% replacement
19% replacement(acid)
10

0
0 1 2 3 4
Number of cubes

5.9.2 BASE TEST:

5.9.2.1 % replacement of cement with brick ash

% Replacement Compressive strength for 28days in

of cement with 28N/mm2
brick ash
Sample 1 Sample 2 Sample 3

16 33.33 34.67 37.33

17 40.89 31.11 31.56

18 35.56 28.89 32.00

19 35.56 34.22 35.11

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16% replacement:

40
28 days compressive strength for base test
35
compressive strength N/mm2

30

25

20
16% replacement
15 16% replacement(base)

10

5
29.2433.33 29.634.67 27.5137.33
0
cube1 cube2 cube3
Number of cubes

40
28 days compressive strength
37.33 for base test
35 34.67
33.33
compressive strength N/mm2

30 29.24 29.6
27.51
25

20
16% replacement
15 16% replacement(base)

10

0
0 1 2 3 4
Number of cubes

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17% replacement:

45
28 days compressive strength for base test
40
compressive strength N/mm2

35

30

25

20 17% replacement
17% replacement(base)
15

10

5
27.0240.89 27.3831.11 26.2231.56
0
cube1 cube2 cube3
Number of cubes

45
28 days 40.89
compressive strength for base test
40
compressive strength N/mm2

35
31.11 31.56
30
27.02 27.38
25 26.22

20 17% replacement
17% replacement(base)
15

10

0
0 1 2 3 4
Number of cubes

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18% replacement:

40
28 days compressive strength for base test
35
compressive strength N/mm2

30

25

20
18% replacement
15 18% replacement(base)

10

5
25.3335.56 24 28.89 25.51 32
0
cube1 cube2 cube3
Number of cubes

40
28 days compressive strength for base test
35 35.56
32
compressive strength N/mm2

30
28.89
25 25.33 25.51
24
20
18% replacement
15 18% replacement(base)

10

0
0 1 2 3 4
Number of cubes

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19% replacement:

40
28 days compressive strength for base test
35
compressive strength N/mm2

30

25

20
19% replacement
15 19% replacement(base)

10

5
25.0235.56 23.11 34 23.7835.11
0
cube1 cube2 cube3
Number of cubes

40
28 days compressive strength for base test
35 35.56 35.11
34
compressive strength N/mm2

30

25 25.02
23.11 23.78
20
19% replacement
15 19% replacement(base)

10

0
0 1 2 3 4
Number of cubes

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Discussions:
For various percent replacement of cement with brick ash it could be seen that for water
curing the compressive strengths achieved is lower than that of conventional M35 mix.
The split tensile strength achieved for different percent replacement is also less
comparatively with normal concrete.
Flexural strength obtained for different % replacement is also less in comparison with the
normal mix.
For the acid test results obtained for strength of cubes kept in water curing is more in
comparison with the acid curing.
Whereas for the base curing the compressive strength obtained is more for the samples
kept in base than those kept in water curing.

From all the above charts, the optimum percentage can be concluded as 16% and the graph
for various parameters is as shown below:

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comparison of optimum % replacement

40

35
compressivve strengths in N/mm2

30

25 normal concrete
16% water cured
20 16% acid cured
16% base cured
15

10

0
cube 1 cube 2 cube 3
number of cubes

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 Experimental Investigation Of Concrete By Partial Replacement Of Cement By Brick Dust.

CHAPTER: 6

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 Experimental Investigation Of Concrete By Partial Replacement Of Cement By Brick Dust.

6. CONCLUSION
The following conclusions would be drawn from the be study:

Brick ash as a waste product from brick kilns factories available in Karnataka or India
would be used as an alternative for cement for cement. Its use in concrete would save to a
great extent 16 percent of cement as binding material, whilst delivering almost identical
compressive strength.
The flexural strength as well as the tensile strength was in good convention with the
values of conventional concrete.
Brick ash has a reddish color which would be aesthetically wonderful.
Use of brick ash in construction would diminish the load on environment.

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 Experimental Investigation Of Concrete By Partial Replacement Of Cement By Brick Dust.

REFERENCES:

1. Use of brick dust in concrete as mineral admixture and partial replacement of cement

by M. Kamal Uddin, Journal of Civil Engineering (IEB), 32(1) (2004) 69-78.

2. A Study on Low Performance Concrete Using Mineral Admixtures (Brick Kiln Dust

and Silica Fumes) by Rajesh Kumar Bharti and Mr. R. D. Patel International Journal for

Scientific Research & Development, Vol. 2, Issue 10, 2014.

3. Assessing the scope of utilizing waste from brick production for building materials by

Salman Siddique, Mohd. ShadabSiddiqui, ShariqMasood Khan. International Journal of

Advanced Technology in Engineering and Science, Volume No 03, Special Issue No. 01, May

2015.

4. Indian Standard Codes:

IS: 10262:2009

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