DURABILITY STUDIES ON M30 GRADE CONCRETE CONTAINING QUARRY SAND AND FLY ASH

International Journal of Civil Engineering and Technology (IJCIET) Volume 8, Issue 4, April 2017, pp. 1696 1705 Article ID: IJCIET_08_04_191 Available online at http://www.iaeme.com/ijciet/issues.asp?jtype=ijciet&vtype=8&itype=4 ISSN Print: 0976-6308 and ISSN Online: 0976-6316 IAEME Publication Scopus Indexed DURABILITY STUDIES ON M30 GRADE CONCRETE CONTAINING QUARRY SAND AND FLY ASH R. S. Deotale Associate Prof, Civil Engineering Department, Yeshwantrao Chavan College of Engineering Nagpur, India Dr.A.M.Pande Director, R&D and Professor Civil Engineering. Department, Yeshwantrao Chavan College of Engineering College, Nagpur, India ABSTRACT The durability of concrete is defined as its ability to withstand weathering action, chemical action, chemical attack or any progressive deterioration. A durable concrete requires little or no maintenance and retains its original form, quality and serviceability when exposed to harsh or aggressive environments. In view of depleting natural resources, quarry sand is recommended as potential substitute for river sand. Source governs the performance of quarry sand in concrete. There is urgent need to investigate durability performance of concrete containing quarry sand available. In this research attempt is made to examine the suitability of replacing cement by fly ash and natural sand by with various percentage of quarry sand for M30 grade concrete. Mix design was carried out and three combinations were chosen, first combination using 100 Natural sand and 100 cement (treated as controlled mix), in second combination 100Natural sand is replaced by Quarry sand and cement remains100 and in third combination 30 cement is replaced by Fly ash and 45 Natural sand is replaced by Quarry sand (treated as critical mix). Comparison of performances of concretes in relevance to durability is presented in the paper. It is observed that 100 replacement of natural sand with quarry sand is not justifiable from durability point of view, especially in relevance to permeable voids formation, RCPT and acid attack; the use of fly ash significantly enhances durability properties of concrete. It is recommended that whenever it is imperative to use quarry sand in concrete, adequate quantity of fly ash must be added as partial replacement of cement to enhance durability of concrete. Key words: Quarry Sand, Fly Ash, Natural Sand, Acid Attack, Permeable Voids. http://www.iaeme.com/ijciet/index.asp 1696 editor@iaeme.com

R. S. Deotale and Dr. A. M.Pande Cite this Article: R. S. Deotale and Dr. A. M.Pande, Durability Studies On M30 Grade Concrete Containing Quarry Sand and Fly Ash. International Journal of Civil Engineering and Technology, 8(4), 2017, pp. 1695 1704. http://www.iaeme.com/ijciet/issues.asp?jtype=ijciet&vtype=8&itype=4 1. INTRODUCTION Concrete is the most widely used construction material in civil engineering industry because of its high structural strength, stability and malleability. The conventional concrete is produced by using natural sand from river bed as fine aggregate. Dwindling sand resources poses the environmental problem and hence government restriction on sand quarrying resulted in scarcity and significant increase in it cost. The concrete industry is constantly looking for supplementary material for concrete. It can be made by partially replacing natural sand with quarry sand. The durability of concrete is also a major concern, as severe exposure conditions can cause concrete to deteriorate, which may result in aesthetic, functional or structural problems. Replacement of natural sand by quarry dust may pose durability problems as chemical composition and physical behavior of this material lies with the source. In general, cement concrete does not have good resistance to acid attack. The product of combustion of many fuel contain sulfurous gases which combine with moisture to form sulfuric acid. Also certain bacteria convert sewage into sulfuric acid. It is particularly aggressive to concrete because the calcium sulfate formed from acid reaction will also deteriorate concrete. Significant detioriation of concrete in sewer system may result in cracking or spalling of concrete and corrosion of reinforcement. M. Uma, S. Shameembanu [1] presented comparison of natural sand and artificial sand with dust, by checking durability properties through the measurement of acid attack on compressive strength. The acid durability factor is more for combined mix containing fly ash and quarry sand as compared to conventional mix. Shaikh and S. A. Daimi [2] studied strength of natural sand and artificial sand with dust by checking durability properties through the measurement of permeable voids, water absorption, acid attack and chloride permeability. They have found that the mixes with the artificial sand with dust as fine aggregate give consistently higher strength than mixes with natural sand and weight loss of artificial sand block is considerably same with respective mixes with natural sand. Nimitha Vijayaraghavan, Dr. A. S. Wayal [3] concluded that resistance to penetration of water is increased with increase in proportion of manufacturing sand and it is proved by rapid chloride penetration test and water permeability test. Asma K.C, Meera C. M., Preetha Prabhakaran [4] investigated the effect of mineral admixtures on the durability properties of high performance concrete to improve the resistance of concrete to penetration of harmful substances such as chloride and sulphate ions, CO2, water and oxygen. The improved pore structure of high performance concrete is mainly achieved by the use of chemical and mineral admixtures K. kewai [5] studied on biological deterioration of concrete in sewage and water treatment plant due sulfuric acid attack and analyzed chemicals present with by XRD and Ion-chromato analyzer. It was found that rate of concrete deterioration depends upon ph value, concentration and exposure time of flowing acid solution. H. Said, H. A. Meshah and Kamli Bernard [6] concluded that flyash addition has better resistance in acid medium and increase of cement content increases the risk of Suphuric attacks. R Nandini, K Mythl [7] concluded that fly ash and micro silica improve resistance to acid attack because it reduces presence of calcium hydroxide which is most vulnerable to acid attack. M.Vijaya sheshar Reddy, IV Rammana Reddy, K Madanmohan Reddy, CM Ravikumar [8] studied Durability aspect of concrete with and without supplementary cementing material and concluded that reduction in compressive strength is observed due to sulphate attack. They have found that fly ash mix has better resistance against acid attack as compared to silica flume mix and meta-kaolin mix. http://www.iaeme.com/ijciet/index.asp 1697 editor@iaeme.com

Durability Studies On M30 Grade Concrete Containing Quarry Sand and Fly Ash In present investigation cement is replaced by fly ash by weight of the quarry sand is used as an alternative fine aggregate material in different proportions. This paper deals with durability properties of M30 grade concrete in terms of Sulphuric Acid attack, Hydrochloric Acid attack, development of permeable voids and Rapid Chloride Ion Permeability tests(rcpt). 2. MATERIALS USED 2.1. Fly ash Fly ash used in the investigation was obtained from Koradi Power Plant Nagpur. Specific gravity of fly ash was 2.29. [ASTM C 618 Class C fly ash] 2.2. Quarry sand The cheapest and the easiest way of getting substitute for natural sand is by crushing natural stone to get artificial sand of desired size and grade which would be free from all impurities is known as Quarry Sand. Quarry Sand was obtained from Sidheshwar quarry, Pachgaon. Plant: 360, Surgaon, Nagpur, specific gravity of quarry sand was 3.09. 2.3. Cement Ordinary Portland Cement of 43 grade used in the investigation (conforming to IS: 12269-1987) having specific gravity of 3.0 2.4. Chemical admixture Super-plasticizer used was.ac-plast-bv 430 (Apple Chemie, Nagpur) as a high range water reducing admixture for obtaining a workable mix. 3. CONCRETE MIX DESIGN The mix design was carried out in accordance with provisions of IS: 10262-2009 for different combinations, for mix M30, details of combinations are presented in table 1. Identification Symbol Identification Text Table 1 Combinations of Concrete Mixes Cement Fly ash 4. EXPERIMENTAL INVESTIGATIONS Natural Sand Quarry Sand 10 mm 4.1. Testing Tests on hardened concrete carried out includes compressive test on concrete cube for size 150mm X 150mm X 150mm (IS: 516 1959). Acid resistance test for hydrochloric acid (HCl) and sulphuric acid (H2SO4) were carried out as per ACTM C-267. In this research permeable voids test is carried out for each sample as per ASTM C-642-97, and RCPT test in accordance with ASTM C1202. The chemical composition of cement paste is determined using XRF analysis, before and after immersion in acidic water. 20mm M-30B Controlled Mix 100-100 - 50 50 M-30G 100 Quarry Sand Mix 100 - - 100 50 50 M-30D3 Critical Mix 70 30 55 45 50 50 http://www.iaeme.com/ijciet/index.asp 1698 editor@iaeme.com

R. S. Deotale and Dr. A. M.Pande 4.2. Acid attack testing of concrete The initial mass and compressive strength of the cubic specimens of 150x150x150 mm was determined after 28 of curing before immersing into the acid solutions. Sulphuric and hydrochloric acid solutions with initial concentrations of 1 by volume were prepared in acidresistant tanks. The 1 H2SO4 water solution (98.5 concentration-5.57ml/liter water) and 1 HCl water solution (36.46 concentration-24.4 ml/liter water) were prepared. The Replicates of specimens from each mixture were kept continuously immersed in the sulphuric and hydrochloric acid solutions for 30, 60, 90 & 120 as recommended by ASTM C 267. During the test period, the cubic specimens were removed after 30, 60, 90 & 120 from solutions, rinsed with tap water and left to dry for 30 min before weighing and visual inspection. The solution was replaced at regular intervals to maintain ph 5 constant throughout. After 30, 60, 90 & 120, the specimens were tested for compressive strength based on the original cross-sectional area. The percentage of strength change were calculated, percentage weight loss and acid durability factor were calculated. 4.3. Chemical analysis of acid affected concrete The chemical composition of an inorganic material was determined by X Ray Fluorescence Analysis (XRF). It provides highly accurate information about elemental mineral composition. 4.4. Permeable voids Test This test method covers the determination of density, percent absorption and percent voids in hardened concrete. The sample consist of any desired shape or size, except that the weight of each portion shall be not less than 800gm and each portion is free from observable cracks, fissures or shattered edges. In this research permeable voids test is carried out for each sample as per ASTM C 642-97. 4.5. Rapid Chloride Ion Permeability Test The rapid chloride ion permeability test (RCPT) is performed as per provisions of ASTM C1202. This standard specifies the rating of chloride permeability of concrete based on the charge passed through the specimen during six hours of testing period. Dry concrete is a semiconductor or insulator. Electrical conductivity of water saturated concrete depends on not only the pore structure and but also the chemistry of pore solution. The transport of chloride ions has little to do with the chemistry of pore solutions, but many factors such as cement composition, aggregate, concrete mixing proportions, use of supplementary cementing materials, chemical additives, etc. can have very significant effects on the concentration of conductive ions in the pore solution. RCPT has been used to evaluate the chloride permeability of hardened cement concretes. 5. DISCUSSIONS 1. Compressive strength gain in critical mix is found similar to that of controlled mix. The gain of compressive strength in case of concrete containing 100 quarry sand is much lower than other two mixes. This clearly indicate that the gain of compressive strength is compromised by using quarry sand, which can then easily be compensated by using fly ash of adequate quantity (as indicated by fig. 1) 2. Development of permeable voids at various ages is much higher in case of mix containing 100 Quarry sand as fine aggregate and that in critical mix lies in between mix containing100 Quarry sand and the controlled mix. This confirms that the fly ash is resulting in pore refinement, as indicated in fig. 2 http://www.iaeme.com/ijciet/index.asp 1699 editor@iaeme.com

Durability Studies On M30 Grade Concrete Containing Quarry Sand and Fly Ash 3. Permeable voids are decreasing with age of curing. Permeable voids (pores) get dissolved as curing period increases due to secondary hydration which increases density. When 100 natural sand is replaced by quarry sand, internal voids (pores) increase. Fly ash reduces the pores as indicated in Fig. 2 4. The fly ash is reacting with calcium hydroxide to form secondary C-S-H and thus helping gain of compressive strength and pore refinement properties. The RCPT results as indicated in fig. 3 justify the results obtained using permeable voids 5. It has been observed that controlled mix is more affected by action of hydrochloric acid and Sulfuric acid and when natural sand is fully replaced by quarry sand. The resistance against acid get reduced due to presence of more amount internal voids and this drawback can be rectified by the use of fly ash, which fills up voids and it will increases resistance against acid. Acid durability factor for critical mix is higher as compared to controlled mix as given in table 2 and table 3. 6. The predominate chemical composition formed due to sulphuric acid and hydrochloric Acid attack are presented in table 5 and the various pigmentation on concrete surfaces as described in table 6 can be seen in photographs 1 and 2. 7. It is observed that percentage weight loss in case of H 2SO 4 attack is significantly more than HCl attack as indicated fig 4 and fig 6. Similar trends have been observed for compressive strength as indicated fig 5 and fig 7. The observations on this test indicate that the weight loss is not significant in case of HCl attack. The HCl attack is less in critical mix as compared to controlled mix. However weight loss and strength loss in H 2SO 4 solution are more. The performance of critical mix is better than controlled mix due to presence of fly ash in critical mix. The leaching of hydrated calcium sulphate (gypsum) observed in case of sulphuric acid attack is observed as white product on exposed surface. Traces of calcium chloride on specimen are observed in concrete exposed to hydrochloric acid attack. 8. It is also observed that action of acid is more at initial stage and once reaction between acid and concrete takes place it results into maximum deterioration of concrete and there after deterioration of concrete will not be significant, though concentration of acidic water maintained same as that of initial stage.(fig 4 and fig 5) 9. During the Hydrochloric acid test, it was observed that the colour of the external surface of the sample is yellow where as the colour of interior was brown, and more damage of surface is observed in conventional concrete (controlled concrete) as compared to critical mix and it has been observed that fly ash concrete has better resistance to acid medium. 10. The sulfuric acid (H 2SO 4) reacts with calcium hydroxide of cement hydrates to produce calcium sulfate salt (White powder). These salts are expanding salts and the pressure that is created during their production will crack the concrete. Identification Symbol Table 2 Acid Durability Factor for 1 HCL Solution Compressive Strength after28 curing(mpa) Compressive Strength after Immersion at various ages (MPa) Acid Durability Factor 30 60 90 120 30 60 90 120 M30-B 35.55 33.77 33.10 30.56 29.60 23.75 46.55 68.62 91.49 M30-G 21.50 19.67 19.67 19.67 19.67 22.87 45.74 64.47 83.26 M30-D3 33.33 30.15 31.59 31.59 31.59 22.61 47.39 71.08 94.78 http://www.iaeme.com/ijciet/index.asp 1700 editor@iaeme.com

R. S. Deotale and Dr. A. M.Pande Identification Symbol Table 3 Acid Durability Factor for 1 H 2SO 4 Solution Compressive Strength after28 curing(mpa) Compressive Strength after Immersion at various ages (MPa) 30 60 90 120 30 Acid Durability Factor 60 90 120 M30-B 35.55 33.80 33.72 33.40 33.40 23.77 47.43 70.46 93.95 M30-G 21.50 19.73 19.53 19.53 19.53 22.94 45.42 68.13 90.84 M30-D3 33.33 32.10 31.93 31.86 31.86 24.08 47.90 71.69 95.59 Table 4 Chemical composition of ingredient of concrete (XRF Analysis) Cement Fly ash Natural Sand Quarry sand Mineral oxide by mass by mass by mass by mass Na 2 O Sodium oxide 0.21 0.20 2.34 7.01 MgO Magnesium oxide 1.84 0.58 0.24 5.89 SiO 2 Silicon dioxide 32.52 56.85 76.93 55.51 Al 2O 3Aluminum trioxide 15.94 32.30 11.07 6.78 Fe O3 Iron trioxide 4.77 4.74 2.28 6.79 CaO Calcium oxide 38.87 0.87 0.97 12.30 SO 3 Sulphur trioxide 1.71 0.26 0.05 0.11 Cl Chlorine 0.01 0.01 0.01 0.03 Table 5 Chemical composition of acid affected concrete (XRF Analysis) Unaffected M30-B M30-G M30-D3 H 2SO 4 HCl Unaffected H 2SO 4 HCl Un- H 2SO 4 affected affected affected affected affected affected HCl affected Minerals oxide Na 2O(Sodium oxide) 2.18 1.12 1.24 3.12 1.24 1.26 2.76 0.98 1.00 MgO(Magnesium oxide) 2.13 2.62 2.92 3.38 3.40 3.49 2.89 2.43 2.69 SiO 2 (Silicon dioxide) 47.37 50.52 48.42 39.41 37.77 38.17 47.42 43.68 47.10 Al 2O 3 ((Aluminum trioxide) 9.27 8.75 9.67 12.11 9.54 9,83 12.91 10.03 10.94 FeO 3 (Iron trioxide) 6.53 7.06 7.52 10.94 10.15 10.75 8.58 7.64 7.86 CaO(Calcium oxide) 20.71 16.50 16.58 19.68 21.91 22.74 16.10 17.65 17.16 SO 3 (Sulphur trioxide) 0.66 3.44 1.29 0.70 3.85 1.01 0.55 5.13 0.97 Cl (Chlorine) 0.04 0.08 0.38 0.06 0.09 0.66 0.05 0.09 0.42 http://www.iaeme.com/ijciet/index.asp 1701 editor@iaeme.com

Durability Studies On M30 Grade Concrete Containing Quarry Sand and Fly Ash Table 6 Acid attack reaction products Sulphuric Acid Attack Minerals oxide Reaction Products Properties Na 2O(Sodium oxide) Sodium sulphate White colored powder MgO(Magnesium oxide) Magnesium sulphate White colored crystalline salt. SiO 2 (Silicon dioxide) Silicon sulphate White and gray colored powder Al 2O 3 ((Aluminum trioxide) Aluminum sulphate White colored powder FeO 3 (Iron trioxide) Iron sulphate Brown color compound CaO(Calcium oxide) Calcium sulphate White colored compound. SO 3 (Sulphur trioxide) --Not affected ----- MnO2(manganese oxide) manganese sulphate Pale pink compound Hydrochloric Acid Attack Na 2O(Sodium oxide) Sodium chloride White color salt MgO(Magnesium oxide) Magnesium chloride White color powder SiO 2 (Silicon dioxide) Not affected --- Al 2O 3 ((Aluminum trioxide) Aluminum chloride Yellow color powder. FeO 3 (Iron trioxide) Ferric chloride Purple red compound CaO(Calcium oxide) Calcium chloride Colorless crystalline solid SO 3 (Sulphur trioxide) Hydrogen chloride Brownish powder. MnO2(manganese oxide) manganese chloride White pinkish crystalline solid Comp. Strength in MPa Compressive Strength Development - M30 Grade Concrete 40.00 35.00 30.00 25.00 20.00 15.00 10.00 5.00 0.00 0 20 40 60 80 100 Age in Days M30-B (Controlled Mix) M30-G M30-D3 (Critical Mix) Figure 1 Compresive Strengths at various ages http://www.iaeme.com/ijciet/index.asp 1702 editor@iaeme.com

R. S. Deotale and Dr. A. M.Pande Permeable Voids in Development of Permeable Voids at Various Ages -M30 Grade Concrete 18.00 16.00 14.00 12.00 10.00 8.00 6.00 4.00 2.00 Charge passed(coulombs) 1600 1400 1200 1000 800 600 400 200 0 Comparison of RCPT Results 1332 1060 1445 1450 1364 1200 0.00 20 30 40 50 60 70 80 90 100 Age in Days M30-B M30-G Mix Types M30-D3 M30-B (Controlled Mix) M30-G M30-D3 (Critical Mix) 28 Days 90 Days Fig 2 Permeable Voids in M30 Grade concrete Fig 3. Rapid Chlorid permeability for M30 Grade concrete Figure 4. Percentage of weight loss after immersion in 1 HCl Solution Figure 5. Percentage of strength loss after immersion in 1 HCl Solution Compressive strength loss 9 8 7 6 5 4 3 2 1 0 Compressive stength loss in M30 concrete after imerssion in 1 H 2 SO 4 solution 30 60 90 120 No. of of immerssion in H 2 SO 4 solution M30-B M30-G M30-D3 Figure 6. Percentage of weight loss after immersion in 1 H 2SO 4 Solution Figure 7. Percentage of Strength loss after immersion in 1 H 2SO 4 Solution http://www.iaeme.com/ijciet/index.asp 1703 editor@iaeme.com

Durability Studies On M30 Grade Concrete Containing Quarry Sand and Fly Ash M30-B M30-G M30-D3 Figure 8 Photographs showing effect of 1H 2SO 4 Solution on M30 concrete at the age of 120 Days M30-B M30-G M30D3 Figure 9 Photographs showing effect of 1HCl Solution on M30 concrete This is due to fact that effect of sulfuric acid is primarily related to actual cement content in the concrete. Incorporation of fly ash in concrete produce low amount of reactive Ca(OH)2, thus the effect sulfuric acid decreases with decrease in cement content. Due sulfuric acid attack calcium sulphate formed and it can react with calcium aluminate phase in cement to form calcium sulphoaluminate which on crystallization can cause expansion and disruption of concrete. Chemicals present in the ingredients play major role in the reaction with acids, presence of higher percentage of Sodium Oxide, Magnesium Oxide and Calcium Oxide in the quarry sand as indicated by table 4 is important. Thus chemical properties of the quarry sand are important from durability point of view. 6. CONCLUSION 1. In view of depletion of natural resources of natural sand quarry sand is propagated as viable alternative to natural sand. However utilization of quarry sand should be carried out carefully, especially in acidic environment. 2. The chemical properties of quarry sand, water demand and physical shape of particles are hampering durability of concrete with quarry sand as an alternative to natural river sand. This draw back can be overcome by using appropriate quantity of fly ash in combination with quarry sand and natural river sand. 3. The use of fly ash significantly reduces the weight loss and loss of compressive strength in concrete containing natural sand and quarry sand. 4. It is recommended that whenever it is imperative to use quarry sand in concrete, adequate quantity of fly ash must be add as partial replacement of cement to enhance durability of concrete. http://www.iaeme.com/ijciet/index.asp 1704 editor@iaeme.com

R. S. Deotale and Dr. A. M.Pande REFERENCES [1] Uma, S. Shameembanu, Strength and durability studies on concrete with flyash and artificial sand, International Journal of Engineering Research and General Science, Vol. 3 (1), Jan-Feb 2015 [2] M. G. Shaikh and S. A. Daimi, Durability studies of concrete made by using artificial sand with dust and natural sand, International Journal of Earth Sciences and Engineering, Vol.4, pp.823-825, 2011 [3] Nimitha Vijayaraghavan, Dr. A. S. wayal, Effect of manufactured sand on durability properties of concrete, American Journal of Engineering Research (AJER). 02(12), pp 437-440 [4] Asma K.C, Meera C.M, Preetha Prabhakaran, Effect of mineral admixtures of durability properties of high performance concrete, International Journal of Engineering Research and Applications, Jan 2014. [5] K. Kawai, S Yamaji, T. Shanmi Concrete deterioration caused by sulfuric acid attack, 10DBMC International Conference on durability of building materials and components lyon (France) 17-20 April 2015. [6] H. Said, H. A. Meshah and Kamli Bernard, Influence of natural Pozzolana on behavior of self compacting concrete under sulphuric and hydrochloric acid attacks, comparative study. The Arabian Journal for science and Engineering, 35(1-B), April 2010, pp183-195 [7] R Nandini, K Mythli, Study of concrete blended with micro silica and flyash, International Journal of Research and Innovation (IJRI), Volume I, Issue II, 29 October 2014 [8] Vijay M Sheshar Reddy, IV Rammana Reddy, K Madanmohan Reddy, CM Ravikumar Durability aspect of standard, International Journal of Structural and Civil Engineering, 2(1), February 2013 [9] IS 10262-2009, IS Method of Mix Design, Bureau of Indian Standards, New Delhi [10] IS 516-1959, Methods of Tests for strength of concrete, Bureau of Indian Standards, New Delhi [11] ASTM C267-(1967) Standard Test Methods for Chemical Resistance of Mortars, Grouts, and Monolithic Surfacing s and Polymer Concretes, American Society for testing and materials, USA. http://www.iaeme.com/ijciet/index.asp 1705 editor@iaeme.com