CHAPTER 4

RESEARCH METHODOLOGY
4.1 Aim of the Experimental Programme

The aim of the experimental programme is to evaluate the properties of concrete

incorporating foundry sand mixed with and without silica fume and Metakaolin, used
as auxiliary cementing materials. The various tests performed on concrete samples are
discussed in this chapter, followed by a brief description about mixture proportion
design and curing procedure adopted.

4.2 Materials Used

4.2.1 Cement
In this work J.K. cement of 43 grade was used for casting cubes and cylinders for all
concrete mixes. The cement was of uniform colour i.e. grey with a light greenish shade
and was free from any hard lumps. The various tests conducted on cement are initial
and final setting time, specific gravity, fineness and compressive strength. Testing of
cement was done as per IS: 8112-1989. The various tests results conducted on the
cement and composition limits of Portland cement are reported in Table 4.1, Table 4.2
and Table 4.3 respectively.

Table 4.1 Physical properties of cement

Characteristics Value obtained Standard Value

Initial setting time(minutes) 42 min Not to be less than 30

minutes
Final setting time 310 minutes Not to be greater than 600
(minutes ) minutes
Fineness (%) 4.9% < 10%

Specific gravity 3.09 -

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 Table 4.2 Compressive strength of cement
Average
Compressive

Compressive
Days Specimen Strength
Strength
2
(N/mm2) (N/mm )
1 35.2
7 35.3
2 36.1
3 34.7
1 42.8
28 44.1
2 44.1
3 45.3

Table 4.3 Chemical Composition of Portland cement (IS: 8112-1989)

Ingredient % Content

Lime 60– 67

Silica 17– 25

Alumina 3– 8

Iron oxide 0.5 – 6

Magnesia 0.1 – 4

Alkalis 0.4– 1.3

Sulphur 1.3

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4.2.2 Coarse aggregate
Locally available coarse aggregates having the maximum size of 10 mm and 20mm
were used in the present work. Testing of coarse aggregates was done as per IS: 383-
1970. The 10mm aggregates used were first sieved through 10mm sieve and then
through 4.75 mm sieve and 20mm aggregates were firstly sieved through 20mm sieve.
They were then washed to remove dust and dirt and were dried to surface dry
condition. The results of various tests conducted on coarse aggregate are given in
Table 4.4 & Table 4.5.

Table 4.4 Physical properties of coarse aggregate

Characteristics Value

Type Crushed

Maximum size 20 mm

Specific gravity( 10mm) 2.704

Specific gravity (20mm) 2.825

Total water absorption (10mm) 1.6432%

Total water absorption (20mm) 3.645%

Moisture content (10mm) 0.806%

Moisture content (20mm) 0.7049%

Fineness modulus (10mm) 6.46

Fineness modulus (20mm) 7.68

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Fineness Modulus of Coarse aggregate (10 mm) = ΣC+500/100 = 146.74+500/ 100 =
6.46.

Table 4.5 Sieve analysis of 20 mm aggregates

Cumulative

Mass
Sieve no. % retained % passing %age
retained (kg)
retained

80 mm - 0.00 100 0.00

40 mm - 0.00 100 0.00

20 mm 0 0.00 100 0.00

12.5 mm 2.1865 72.883 27.117 72.883

10 mm 0.6745 22.483 4.634 95.366

4.75 mm 0.1390 4.633 0.01 99.999

Pan 0 0.00 - -

C= 268.244

Fineness Modulus of Coarse aggregate (20mm)= ΣC+500/100 = 268.244+500/ 100 =

7.68.
4.2.3 Fine Aggregate

a) Ordinary Sand

The sand used for the experimental programme was locally procured and conformed to
grading zone III as per IS: 383-1970. The sand was first sieved through 4.75 mm sieve
to remove any particles greater than 4.75 mm and then was washed to remove the dust.
Physical properties and sieve analysis of fine aggregates are listed in Table 4.6 and
Table 4.7.

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 Table 4.6 Physical properties of fine aggregates

Characteristics Value

Type Uncrushed (natural)

Specific gravity 2.68

Total water absorption 1.02 %

Moisture content 0.16 %

Net water absorption 0.86 %

Fineness modulus 2.507

Grading zone Zone III

Table 4.7 Sieve analysis of fine aggregate

Sieve size Retained, %age

Retained, % Passing, %
(gms) Retained

4.75 mm 95.0 9.5 90.5 9.5

2.36 mm 42.5 4.25 86.25 13.75

1.18 mm 110.5 11.05 75.2 24.8

600 m 128.5 12.85 62.35 37.65

300 m 308.0 30.8 31.55 68.45

150 m 281.0 28.1 3.45 96.55

Pan 34.5 3.45 -

ΣF = 250.7

Total weight taken = 1000gms

Fineness Modulus of fine aggregate = ΣF/100 = 250.7/100 = 2.507

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b) Foundry Sand

Investigations were made on foundry sand procured from Insaf Foundries, Mandi
Gobindgarh, Punjab. Sieve analysis of fine aggregates at 10% replacement level is
give in Table 4.8.

Table 4.8 Sieve analysis of Fine Aggregates at 10% replacement level

Mass Retained Cumulative %age

Sieve No. % Retained % Passing
(gms) retained

4.75 mm 37.0 3.7 96.3 3.7

2.36 mm 10.5 1.05 95.25 4.75

1.18 mm 43.0 4.3 90.95 9.05

600 mm 67.5 6.75 84.2 15.8

300 mm 23.90 2.390 60.3 39.7

150 mm 54.90 5.490 5.4 94.6

Pan 5.15 0.515 0.25 99.75

267.35

Fineness Modulus of fine aggregates with 10% foundry sand = ΣF/100 =267.35/100 =
2.6.

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4.2.4 Silica fume
Densified silica fume obtained from KGR agro Fusions Pvt. Ltd, Hambran, Ludhiana,
Punjab is used in this work. It was grey in colour. It is shown below in Fig 4.1.

Fig. 4.1 Silica Fume mixed with cement

4.2.5 Metakaolin
The metakaolin used in this study is Metacem of grade 85-C, obtained from
Amorphous Chemicals Private Limited, New Delhi. It was pinkish white in colour and
is shown below in Fig. 4.2.

Fig. 4.2 Metakaolin

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4.2.6 Water
Potable tap water was used for the concrete preparation and for the curing of
specimens.

4.2.7 Admixture
Admixture used in this work is Conplast SP430, which complies with IS-9103:1979
and BS:5075 Part 3 and ASTM-C-494 type ‘F’ as a high range water reducing
admixture. Conplast SP 430 is a ready to use admixture that is added to the concrete at
the time of batching. Conplast SP430 is differentiated from conventional super
plasticizers in that it is based on aqueous solution of lingo sulphonates, organic
polymer with long lateral chains. This greatly improves cement dispersion. Conplast
SP430 is supplied as brown liquid instantly dispersible in water and specially
formulated to give high water reduction up to 25% without loss of workability.
Specific gravity is 1.22 to 1.225 at 30º C.

4.2.8 Magnesium Sulphate

Powder form of magnesium sulphate was obtained from Scientific Junction, Patiala. It
was white in colour. Its solution of strength 5% by adding it to water was made and
used for sulphate resistance test.

Fig. 4.3 Magnesium Sulphate

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4.3 Mixture Proportioning
Table 4.9 Various Mix proportions

Mixture C.M C.M1 M1 M2 M3 M4 M5 M6

Cement(Kg/cum) 372 372 353 335 316 353 335 316

Silica fume (%) 0 0 5 10 15 - - -

Silica
0 0 19 37 56 - - -
fume(Kg/cum)

Metakaolin (%) 0 0 - - - 5 10 15

Metakaolin
0 0 - - - 19 37 56
(Kg/cum)

Sand
539 485 485 485 485 485 485 485
(Kg/cum)

Foundry sand
0 10 10 10 10 10 10 10
(%)

Foundry sand
0 54 54 54 54 54 54 54
(Kg/cum)

C.A 10mm
410 410 410 410 410 410 410 410
(Kg/cum)

C.A 20mm
819 819 819 819 819 819 819 819
(Kg/cum)

Water(Kg/cum) 186 186 186 186 186 186 186 186

W/C 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

SP(Kg/cum) 4.5 5.9 5.9 5.9 5.9 5.9 5.9 5.9

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4.4 Batching, Mixing and Casting of Specimens.
Cubical moulds of size 150mm³ were used to prepare the concrete specimens for the
determination of compressive strength of concrete. Care was taken during casting and
vibrator was used for proper compaction. Cylindrical moulds of size 150 mm # 300
mm were used to prepare the concrete specimens for the determination of split tensile
strength of concrete. All the specimens were prepared in accordance with Indian
Standard Specifications IS: 516-1959. All the moulds were cleaned and oiled properly.
These were securely tightened to correct dimensions before casting.

A careful procedure was adopted in the batching, mixing and casting operations. The
coarse aggregates and fine aggregates were weighed first with an accuracy of 0.5
grams. The concrete mixture was prepared by hand mixing on a non-absorbing
platform. PPC having 43 grades was used in casting. Fine aggregates are replaced with
10% foundry sand and thoroughly mixed. After that coarse aggregates are added to it.
Super plasticizer as per requirement was added to required quantity of water separately
in different containers. Then water was added carefully so that no water was lost
during mixing. For each mix 27 samples were prepared which consists of 9 cubes
(150*150*150 mm) for 7, 28 and 56 days compressive strength, 9 cubes (150 * 150 *
150mm) for 7, 28 and 56 days sulphate resistance test and 9 cylinders (300 *150mm)
for split tensile strength at 7, 28 and 56 days. Vibrations were stopped as soon as the
cement slurry appeared on the top surface of the mould. The specimens were allowed
to remain in the steel mould for the first 24 hours at ambient condition. After that these
were de-moulded with care so that no edges were broken and were placed in the
curing tank at the ambient temperature for curing. The ambient temperature for curing
was 27 ± 20℃. (IS: 10262-1982).

4.5 Experimental Procedure

4.5.1 Testing the compressive strength and splitting tensile strength
of concrete
Firstly, measured quantity of 20mm and 10mm coarse aggregates are mixed together.
Ordinary sand is replaced with 10% waste foundry sand on a separate platform which
is kept constant in all the mixes, and then fine aggregates are mixed with coarse
aggregates. Cement mixed with desired silica fume content is then added to the

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mixture. Super plasticizer SP - 430 is added to the water of desired quantity and this
water is then finally added to the mix. This final concrete mixture was then put into
properly oiled and fitted steel moulds (cubes of 150 ) in layers and then placed on a
vibrator for proper settlement of concrete. After the cubes were casted, they were left
for 24 hours in normal room temperature before de moulding. And finally, the cubes
were placed in the water curing tank and taken out after 7, 28 and 56 days respectively
to get the compressive strength test readings for each mix.

4.5.2 Testing the Sulphate resistance of concrete

For this, 24 cubes each of size 150 were prepared (3 cubes for each mix) for testing the
decrease or increase in compressive strength due to external sulphate attack on the
concrete specimen. The cubes were first water cured for 28 days after de-moulding.
Then after 28 days of curing, the cubes were immersed in 5% MgSO4 solution for 7,
28 and 56 days respectively. Finally the compressive strengths of these cubes were
examined at 7, 28 and 56 days of immersion period.

4.6 Tests to be performed for cubes and cylinders (to control

as well as mixed concrete)
The tests for the proposed study will be conducted at the Materials Testing Lab of
Department Of Civil Engineering, Shree Siddhivinayak Group Of Institutions,
Shahpur Haryana, India. Tests for the comparison and variations are as follows:

(1) Compression strength test

(2) Split tensile strength.

(3) Sulphate resistance test.

4.6.1 Compressive Strength Test (IS: 516 – 1959)

This test is performed on cube specimens to determine compressive strength at various
ages.

Apparatus

Compression Testing Machine - The testing machine may be of any reliable type, of
sufficient capacity for the tests and capable of applying the load at the rate specified.

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The permissible error shall be not greater than ± 2 percent of the maximum load. The
testing machine shall be equipped with two steel bearing platens with hardened faces.
One of the platens (preferably the one that normally will bear on the upper surface of
the specimen) shall be fitted with a ball seating in the form of a portion of a sphere, the
centre of which coincides with the central point of the face of the platen. The other
compression platen shall be plain rigid bearing block. The bearing faces of both
platens shall be at least as large as, and preferably larger than the nominal size of the
specimen to which the load is applied.

Age at Test

Tests shall be made at recognized ages of the test specimens, the most usual being 7
and 28 days. Test at age of 56 days can also be performed. Ages of 13 weeks and one
year are recommended if tests at greater ages are required. Where it may be necessary
to obtain the early strengths, tests may be made at the ages of 24 hours ± ½ hour and
72 hours ± 2 hours. The ages shall be calculated from the time of the addition of water
to the dry ingredients.

Number of Specimens

At least three specimens, preferably from different batches, were made for testing at
each selected age.

4.6.2 Splitting Tensile Strength Test (ASTM C496)

This test is performed on cylinder specimen to evaluate its tensile strength at various
different ages.

Apparatus

Compression Testing Machine

Bearing Strips - 2 each, 1/8 in. thick plywood strips, 1 in. wide (the length shall be
slightly longer that of the specimens). The bearing strips are placed between the
specimen and the upper and lower bearing blocks of the testing machine (or between
the specimen and supplementary bearing bars if used).

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Supplementary Bearing Bars - Steel bar 2 inches wide, 3 inches thick, and 12 inches
long.

Procedure

(a) Draw diametric lines on each end of the specimen so that they are in the same axial
plane.

(b) Centre one of the plywood strips along the centre of the lower bearing block.

(c) Place the specimen on the plywood strip and align so that the lines marked on the
ends are vertical and centered over the plywood strip.

(d) Place the second plywood strip and the bearing bar so that they are lengthwise on
the cylinder, centred on the previously marked lines on the ends.

(e) Apply the load continuously at a constant rate of 100 to 200 psi/minute of splitting
tensile stress until failure occurs (the load rate is 11000 to 22000 lb/minute for
6”diameter by 12” long specimens).

(f) Record the maximum load at failure.

(g) Calculate the splitting tensile strength as follows:

2P

fst' =
π ld

Where P is the maximum load at failure in pounds, and l and d are the length and
diameter of the cylindrical specimen, respectively, in inches.

Report

(a) Report the type of concrete, unit weight, and unconfined compressive strength.

(b) Report the splitting tensile strength to the nearest 5 psi.

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4.6.3. Sulphate Resistance Test

Tests performed for sulphate resistance in this work are compressive strength test after
immersing the cube specimen in 5% magnesium sulphate solution for 7, 28 and 56
days. Before immersing them in sulphate solution, specimens are cured for 28 days in
water under normal temperature. Compressive strength test has been already discussed
above in article 4.6.1.

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