IRJET- To Study the Suitability and Performance of Expanded Perlite Aggregate with Partial Replacement of Crushed Rock Fines as Fine Aggregate
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This document presents the results of an experimental study investigating the use of expanded perlite aggregate (EPA) as a partial replacement for crushed rock fines (CRF) in concrete. Different mixing procedures were tested to determine the optimal method. Concrete mixtures were prepared with EPA replacing CRF at levels from 5% to 25%. The fresh and hardened properties of the concrete mixtures were evaluated through tests like slump, density, compressive strength, split tensile strength, and flexural strength. Durability was assessed using tests for water permeability, rapid chloride permeability, acid resistance, and sorpitivity. Exposure to different temperatures over time was also studied. The results showed that a 10% replacement of CRF with EPA provided increases in strength
IRJET- To Study the Suitability and Performance of Expanded Perlite Aggregate with Partial Replacement of Crushed Rock Fines as Fine Aggregate
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 881 To Study the Suitability and Performance of Expanded Perlite Aggregate with Partial Replacement of Crushed Rock Fines as Fine Aggregate Sinchana H.K1, K.E Prakash2 1PG Student Department of Civil Engineering SDIT Kenjar, Mangaluru, India. 2PG Director Shreedevi Institute of Technology, Kenjar, Mangaluru, India. ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - This project is carried out to extract the results of experimental work, carried out to investigate the optimum percentage of EPA in concrete to partially replace CRF which was used as fine aggregates effectively. Different mixing procedures of mixing of EPA with the CRF are also studied in order to attain more strength in the concrete. The different tests carried out in present work are workability property by slump cone test, density of concrete, mechanical properties by compressive strength test, Split tensile strength test, flexural strength test and durability test by Water permeability test, Rapid Chloride Permeability test, Acid Resistivity test, Sorpitivity test and the strength deterioration by the concrete exposed to different temperature and different duration is studied. The experimental work is carried out to determine the optimum percentage of EPA to replace the CRF effectively in concrete. In the first phase the mixing procedures of the concrete with EPA is studied and the strength is resulted. In the second stage, the optimum percentage of EPA that can be added to replace CRF is studied according to strength. In the third stage, durability tests of the optimum percentage of EPA mixed concrete is studied, in the fourth stage, the strengthloss due to the exposure of different temperature to different duration is studied. Key Words: Light Weight Concrete, Expanded Perlite Aggregates, Crushed Rock Fines 1. INTRODUCTION 1.1 GENRAL Concrete is made up of mixing cement, gravel, sand and water. Concrete is being used in many purposes to make it suitable in different conditions. The higher self-weightisthe great disadvantage of conventional concrete. Around 2200kg/m3 to 2600kg/m3 isthedensityofnormal concrete. This weight is heavy as per its self-weight so it is termed as uneconomical. Many attempts have been made in thepastto decrease the self-weight of the concrete. Reduced structural weight helps in higher economy Expanded perlite aggregates (EPA) due to its low density, high absorption, low thermal and acoustic conductivity and very light weight property have much scope in construction sector. Perlite is the common name used for the naturally occurring siliceous rock. 1.2 AIM The major aim of the project is to study the suitability of concrete mix procedures, durability and performance of Expanded Perlite Aggregates based concrete with the replacement of crushedrock fines(CRF)asfineaggregatesin the concrete production. 1.3 OBJECTIVE OF PROJECT 1. To study and evaluate the behavior of EPA when added with the CRF in fresh state. 2. To study and evaluate the behavior of EPA when added with the CRF in hardened state. 3. To ascertain the structural behavior of the concrete using EPA. 4. To study the durability properties such as Sorpitivity, Water Permeability, RCPT & Acid Resistance. 5. To study the improvement in the properties of concrete with normal CRF and with partial replacement of CRF by EPA. 6. To know the suitable mixing procedure so as to obtain maximum strength in hardened concrete obtained with the replacement of EPA. 7. To generate more durable concrete. 8. To enhance the strength of the concrete where it is exposed to different exposures and durations of temperatures. 1.4 SCOPE OF THE PROJCECT The main scope of the project work is to evaluatethevarious properties of the concrete by varying the percentage of Expanded Perlite Aggregate with the Crushed Rock Fines.
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 882 2. MATERIALS USED The material properties used for making of motors is discussed. Physical andchemical propertiesofall ingredients used for the entire experimental work are resulted in this section. The raw materials used in the present investigation is, 1. Cement 2. Coarse aggregates 3. Crushed rock fines 4. Expanded perlite aggregate 4. Bonding agent 5. Water 3. STEPS CHOSEN FOR MIXING THE CONCRETE The strength of concrete varies with the addition of EPA asa partial replacement of CRF was tended to vary with the mixing procedures. So a study was made in order to choose the suitable mixing procedures for the higher compressive strength gain. Table 3.1 Procedure for mixing the concrete Mix Step 1 Step 2 Step 3 Step 4 M1 Adding gravel, CRF, cement Mixed for 5 min Adding water Mixed for 5 min M2 Adding water, cement Mixed for 5 min Adding gravel, perlite, sand Mixed for 5 min M3 Adding water, cement, perlite, sand Mixed for 5 min Adding gravel Mixed for 5 min M4 Adding water, sand, cement Mixed for 5 min Adding perlite, gravel Mixed for 5 min M5 Adding sand , cement, gravel, perlite, half of water Mixed for 5 min Adding another half of water Mixed for 5 min Table 3.2 Compressive strength of different mixing procedures of concrete Mix Compressive Strength (MPa) M1 34.91 M2 24.3 M3 35.25 M4 34.8 M5 22.36 Since the compressive strength is maximum for M3 mixing procedure that is with the addition of water, perlite, sand, cement, and mixing it for 5 minutes then adding gravel and mixing 5 minutes is suitable considering the other types of mixing procedures. 4. MIXPROPORTIONSFORTHEADDITIONOFEXPANDED PERLITE AGGREGATES TO REPLACE WITH FINE AGGREGATES (FA) The mix proportions for the addition of expanded Perlite aggregates have been tabulated below. EPA signifies expanded Perlite aggregates. The concrete cubes casted for different percentages EPA and the investigations will be carried out with respect to the Fresh and hardened properties of concrete. Table 3.14 Designation and Mix Proportions Mix Proportions Designation Percentage replacement C1 CRF AGGREGATES TM1 95% CRF + 5% EPA TM2 90% CRF + 10% EPA TM3 85% CRF + 15% EPA TM4 80% CRF + 20% EPA TM5 75% CRF + 25% EPA 5 RESULTS AND DISCUSSION 5.1 WORKABILITY TEST ON CONCRETE The workability test is been conducted as per IS: 1199-1959 for the various replacement percentages of SSS and also for the conventional concrete.
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 883 Table 5.1 Slump values for the replacement of EPA Sl. No . Design ation Percentage replacement Slump value (mm) 1 C1 CRF AGGREGATES 100mm 2 TM1 95% CRF + 5% EPA 90mm 3 TM2 90% CRF + 10% EPA 95mm 4 TM3 85% CRF + 15% EPA 60mm 5 TM4 80% CRF + 20% EPA 45mm 6 TM5 75% CRF + 25% EPA 30mm Figure 5.1 Slump Test Results 5.2 BULK DENSITY TEST As per the procedure of IS-1199 Method of sampling and analysis of concrete is used. Table 5.2 Bulk Density Test results for the replacement of EPA Sl. No. Desig nation Percentage Replacement Wet density (kg/m3) Dry density (kg/m3) 1 C1 CRF AGGREGATES 2382 2381 2 TM1 95% CRF + 5% EPA 2338 2322 3 TM2 90% CRF + 10% EPA 2255 2223 4 TM3 85% CRF + 15% EPA 2187 2139 5 TM4 80% CRF + 20% EPA 2139 2075 6 TM5 75% CRF + 25% EPA 2094 2021 2338 2255 2187 2139 2094 2322 2223 2139 2075 2021 1850 1900 1950 2000 2050 2100 2150 2200 2250 2300 2350 2400 95% CRF + 5% EPA 90% CRF + 10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF + 25% EPA Densityinkg/m3 Percentage replacement Bulk Density Wet density Dry density Figure 5.2 Bulk Density test results 5.3 COMPRESSIVE STRENGTH TEST The determination of compressive strength was carried out as per standard practice IS 4031(part 6-1988). Table 5.3 Compressive Strength results for the replacement of EPA Sl. No. Mix Designation Percentage Replacement Average compressive strength(N/mm2) 7 days 14 days 28 days 1 C1 CRF AGGREGATES 19.82 29.28 33.66 2 TM1 95% CRF + 5% EPA 17.08 26.10 32.40 3 TM2 90% CRF + 10% EPA 22.30 26.70 34.74 4 TM3 85% CRF + 15% EPA 20.23 24.52 33.33 5 TM4 80% CRF + 20% EPA 13.83 21.74 25.96 6 TM5 75% CRF + 25% EPA 12.54 19.58 21.36
- 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 884 19.82 17.08 22.3 20.23 13.83 12.54 0 5 10 15 20 25 CRF 95% CRF + 5% EPA 90% CRF + 10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF + 25% EPA AverageCompressiveStrengthin N/mm2 Percentage Replacement 7 DAYS COMPRESSIVE STRENGTH Figure 5.3 Compression Strength Test Results for 7 days curing 29.28 26.1 26.7 24.52 21.74 19.58 0 5 10 15 20 25 30 35 CRF 95% CRF + 5% EPA 90% CRF + 10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF + 25% EPA AverageCompressiveStrengthin n/mm2 percentage Replacement 14 DAY COMPRESSIVE STRENGTH Figure 5.4 Compression Strength Test Results for 14 days curing 33.66 32.4 34.74 33.33 25.96 21.36 0 5 10 15 20 25 30 35 40 CRF 95% CRF + 5% EPA 90% CRF + 10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF +25% EPA AverageCompressiveStrength inN/mm2 Percntage Replacement 28 DAYS COMPRESSIVE STRENGTH Figure 5.5 Compression Strength Test Results for 28 days curing The strength parameters in the compressive strength of concrete for 7 days, 14 days and 28 days is shown in the above graphs. From the graph we can note that the compressive strength increases up to 10% replacement of EPA but with 15%, 20% and 25% the compressive strength decreases. EPA being the light weight aggregate has less compression strength compared to other aggregates. 2.34% increment in the compressive strength is found at 10% replacement of CRF by EPA at 28 days when compared to normal concrete with the replacement of fine aggregate with CRF. Partial replacement percentage of EPA up to 10% was found to be beneficial. 5.4 SPLIT TENSILE STRENGTH TEST The determination of Split tensile strength of the prepared samples was carried out as per standard practice. The following table shows the average split tensile strength of various samples after testing. Table Table: 5.4 Split Tensile Strength results 1.25 1.3 1.48 1.42 1.35 1.22 0 0.5 1 1.5 2 CRF 95% CRF + 5% EPA 90% CRF + 10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF + 25% EPA Averagesplittensilestrength inn/mm2 percentage replacement 7 DAYS SPLIT TENSILE STRENGTH Figure 5.6 Split Tensile Strength results for 7 days Sl. No. Mix Desi gnati on Percentage Replacement Average Split tensile strength(N/mm2) 7 days 14 days 28 days 1 C1 CRF AGGREGATES 1.25 1.79 3.18 2 TM1 95% CRF + 5% EPA 1.30 1.57 2.91 3 TM2 90% CRF + 10% EPA 1.48 2.34 3.12 4 TM3 85% CRF + 15% EPA 1.42 2.05 2.76 5 TM4 80% CRF + 20% EPA 1.35 1.68 2.07 6 TM5 75% CRF + 25% EPA 1.22 1.52 1.92
- 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 885 Figure 5.7 Split Tensile Strength results for 14 days Figure 5.8 Split Tensile Strength results for 28 days From the results obtained for the split tensile strength test, the higher split tensile strength is obtained for the 10% replacement of EPA by the CRF. In hardened concrete tests as the replacement percentage increases the strength also increases but up to certain limit beyond that the strength reduces as the percentage of replacement increases. 5.5 FLEXURAL STRENGTH TEST The determination of Flexural strength of the prepared samples was carried out as per standard practice. The following table shows the average Flexural strength of various samples after testing.InthiscaseFineaggregates are replaced by partial amount of EPA. Table 5.5 Flexural strength results for the replacement of EPA Figure 5.9 Flexural Strength results for 7 days The Strength parameters in the Flexural strengthofconcrete for 7 days, 14 days and 28 days is shown in the above graphs. From the graph we can note that the Flexural strength increases up to 10% replacement of EPA and 90% CRF but with 15%, 20% and 25% the strength decreases gradually. Sl. No. Mix Designation Percentage Replacement Average Flexural strength in N/mm2 7 days 14 days 28 days 1 C1 CRF AGGREGATES 2.34 3.20 5.75 2 TM1 95% CRF + 5% EPA 1.91 2.72 5.18 3 TM2 90% CRF + 10% EPA 3.26 2.94 5.55 4 TM3 85% CRF + 15% EPA 2.88 2.81 5.21 5 TM4 80% CRF + 20% EPA 2.15 2.56 4.48 6 TM5 75% CRF + 25% EPA 2.24 2.08 3.92
- 6. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 886 3.2 2.72 2.94 2.81 2.56 2.08 0 0.5 1 1.5 2 2.5 3 3.5 CRF 95% CRF + 5% EPA 90% CRF +10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF + 25% EPA AverageFlexuralStrength N/mm2 Percentage Replacement 14 DAYS FLEXURAL STRENGTH Figure 5.10 Flexural Strength results for 14 days 5.75 5.18 5.55 5.21 4.48 3.92 0 1 2 3 4 5 6 7 CRF 95% CRF + 5% EPA 90% CRF + 10% EPA 85% CRF + 15% EPA 80% CRF + 20% EPA 75% CRF + 25% EPA AverageFlexuralStrengthin N/mm2 Percentage Replacement 28 DAYS FLEXURAL STRENGTH Figure 5.11 Flexural Strength results for 28 days From the results obtained for the Workability test, Compressive strength test, Flexural strength test and Split tensile strength test the optimumreplacementpercentageof EPA to replace Fine aggregates is 10%. Fromtheworkability test results obtained it is seen that, the slump decreases as the replacement percentage increases but up to certainlimit only i.e., up to 5%. At 10% there will be slight increase in the workability. Beyond this replacement limit there is no improvement in workability. 5.6 DURABILITY TESTS The durability tests are conducted on control mix and 90% CRF + 10% EPA = M2 mix, based on slump and compressive strength results. The various durability test results are illustrated below. 5.6.1 WATER PERMEABILITY TEST The test is carried out on 150 mm× 150 mm× 150 mm specimens after 28 days of curing in water. Thesespecimens are usually subjected to 5 bar pressure for72hours.After 72 hours the depth of water penetration is recorded using water penetrometer. Table 5.6 Water Permeability test results Figure 5.12 Water Permeability test results 5.6.2 RAPID CHLORIDE PERMEABILITY TEST (RCPT) The electrical conductance of samples includes measuring the charges in coulombs to give a rapid result of its resistance to penetration of chloride ion. The RCPT test results are as follows. Table 4.7 RCPT test results Mix Designation Percentage Replacement RCPT Values in Coulombs C1 100% CRF 1215.4 TM2 90% CRF + 10% EPA 792.5 1215.4 792.5 0 500 1000 1500 100% CRF 90% CRF + 10% EPA RCPTValuesinCoulombs Percentage Replacement RCPT Figure 5.13 RCPT test results Mix Designation Percentage Replacement Depth of Penetration (mm) C1 100% CRF 10.08 TM2 90% CRF + 10% EPA 6.55
- 7. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 887 5.6.3 ACID RESISTIVITY TEST The loss in weight of samples is the difference between the mass of sample before immersion and the mass of sample after immersion in acid. The test results after submerging the samples for 90 days in H2SO4 solution is shown in the table below. Table 5.8 Acid Resistivity test results Mix Design ation Percentage Replacement Weight Before Immersi on (kg) Weight After 90 days of Immersi on (kg) Loss in Weig ht (kg) C1 100% CRF 7.832 7.584 0.248 TM2 90% CRF + 10% EPA 8.054 7.758 0.296 7.832 7.584 0.248 8.054 7.758 0.296 0 5 10 Weight before immersion Weight after 90days of immersion Loss in weight Weightinkg A C ID R E S IS T IV IT Y T E S T 100% CRF 90% CRF + 10% EPA Figure 4.14 Acid resistivity test results 5.6.4 SORPTIVITY TEST Table 5.9 Sorptivity test results Mix No. Perce ntage Repla ceme nt Water absorbed by capillarity (kg) 15 mi n 30 min 1 hou r 24 hou rs 48 hou rs 72 hou rs C1 100% CRF 0.0 00 20 0.00 026 0.00 039 0.00 044 0.00 048 0.00 058 TM2 90% CRF+ 10% EPA 0.0 00 08 0.00 013 0.00 018 0.00 032 0.00 036 0.00 045 Figure 5.15 Sorpitivity test results 6. CONCLUSIONS 1. EPA fulfills the basic properties of fine aggregate. Hence it could be used as replacement for fine aggregate. 2. The suitable mixing of a concrete is found to be as adding water, cement, perlite and sand first, mixing it for 5 minutes and then adding the gravel andmixingit for 5 minutes. 3. From the workabilityanddensitycheck consequences it could be concluded that the workability of the concrete increases in the addition of 10% EPA & 90% of CRF. 4. From the outcomes, it can be concluded that strength in compression, tension and flexure will increase through adding 10% of EPA & 90% of CRF, but the strength decreases as % replacement of EPA increases. 5. Optimum mix of 10% EPA and 90% CRF gives better workability and improved flexural, compressive strength, and split tensile strength. 6. The durability tests Water Permeability, Rapid Chloride Permeability Test, Acid Resistivity and Sorptivity showed good results compare to normal concrete as combination of CRF and EPA is better and strong compared to 100% CRF. 7. The density of the concrete deceased with increase of EPA to the concrete when compared to 100% CRF. 7. SCOPE OF FUTURE STUDY 1. Various effects of other mineral admixtures such as Silica fume Fly ash, and Rice husk ash) mixturewith perlite aggregate can be carried out. 2. Resistance to various other chemical attacks can be studied. 3. Studies can be carried out on structural behavior (beam and column) of perlite mixed concrete. 4. Determination of strength of perlite aggregate mixed concrete can be done for different grades of concrete
- 8. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 05 Issue: 10 | Oct 2018 www.irjet.net p-ISSN: 2395-0072 © 2018, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 888 5. Other characteristics of strength and durability of concrete can be evaluated by different tests. 6. Recuring of the concrete after exposure to temperature can also be studied. REFERENCES 1. Atila Gurhan Celik, Ahmet Mahmut Kilie, Gaye O Cakal “Expanded perlite aggregate characterization for use as a lightweight construction raw material” Research Gate Physicochemical Problems of Mineral Processing ISSN 1643-1049 (print) ISSN 2084-4735 (online) Received: July 1, 2012; revised version received: February 15, 2013; accepted: February 27, 2013. 2. Bhuvaneshwari. K, dr. Dhanalakshmi. G, kaleeswari. G “Experimental study on lightweight concrete using perlite” International research journal of engineering and technology (irjet) volume: 04 issue: 04 | e-ISSN: 2395 -0056 p-ISSN: 2395-0072 April -2017 3. IS Code: 456-2000 Plain and Reinforced Concrete, code of practice. 4. IS Code: 10262-2009 and IS 10262-1982 for concrete mix proportion. 5. Malek Jeddi, Omrane Benjeddou and Chokri Soussi, “ Effect of Expanded Perlite Aggregate dosage on properties of Light weight concrete”, Jordan Journal of Civil Engineering Volume 9, No 3, 2015. 6. M B Karakoc, R Demin boga, I Turkmen, I Can , “Effect of expanded perlite aggregate on cyclic thermal loading of HSC and artificial neural network modeling” Scientia Iranica, Vol 19, Issue 1, Feb 2012. 7. Mesut Aşik “Structural Lightweight concrete with natural perlite aggregate and perlite powder” a thesis submitted to the graduate school of natural and applied sciences of Middle East technical university in September 2006 8. M Vijaya Shekhar Reddy, I V Ramanna Reddy, K Madan Mohan Reddy and C M Ravikumar“International Journal of Structural and Civil Engineering research Vol 2, No 1, Febrauary 2013.