CONTENTS

[Link] TITTLE PAGE NO

1. ABSTRACT 1

2. INTRODUCTION 4

1. OVERVIEW 5

2. ORDINARY PORTLAND CEMENT 6

3. INTRODUCTION TO CEMENT CONCRETE 8

4. PROPERTIES OF CONCRETE 9

5. SCOPE OF WORK 10

6. SUGARCANE BAGASSE 11

7. HCL ATTACK 12

3. LITERATURE REVIEW 15

4. METHODOLOGY 31

5. EXPERIMENTAL INVESTIGATION 33

1. INTRODUCTION 34

2. MATERIALS USED 34

6. MIX PROPORTION 50
7. RESULTS AND DISCUSSIONS 55

8. CONCLUSIONS 63

9. REFERENCES 64
 LIST OF TABLES

TABLE NO. TITTLE PAGE NO.

I. Sieve Analysis of Coarse Aggregate 47

II. Sieve Analysis of Fine Aggregate 48

III. Physical Properties of Fine and Coarse 48

Aggregate

IV. Workability of Concrete 49

V. Compressive Strength Results 56

(M30 in normal Water)

VI. Compressive Strength Results 56

(M30 in HCL)

VII. Reduction in Compressive Strength 57

Under HCL Attacking for 7 days

VIII. Reduction in Compressive Strength 57

Under HCL Attacking for 14 days

IX. Reduction in Compressive Strength 58

Under HCL Attacking for 28 days

X. Split Tensile Strength Results 62

ABSTRACT

1
 We are aware that a lot of damage is done to environment in the

manufacture of cement. It involves lot of carbon emission associated

with other chemicals. The researches has shown that every one ton of

cement manufacture releases half ton of carbon dioxide, so there is an

immediate need to control the usage of cement. On the hand materials

wastes such as Sugar Cane Bagasse Ash is difficult to dispose which

in return is environmental Hazard.

The Bagasse ash imparts high early strength to concrete and also

reduce the permeability of concrete. The Silica present in the Bagasse

ash reacts with components of cement during hydration and imparts

additional properties such as chloride resistance, corrosion resistance

etc. Therefore the use of Bagasse ash in concrete not only reduces the

environmental pollution but also enhances the properties of concrete

and also reduces the cost. It makes the concrete more durable

This project mainly deals with the replacement of cement with

Bagasse ash in fixed proportions and analysing the effect of HCL on

SCBA blended concrete. The concrete mix designed by varying the

2
proportions of Bagasse ash for 0%, 5%, 10%, 15%, 20% ,25% the

cubes are been casted and cured in normal water and 5% HCL

solution for ages of 7, 14 and 28 days. The test result indicate that the

strength of concrete increase up to 10% Sugar cane bagasse ash

replacement with cement.

3
INTRODUCTION

4
 OVERVIEW

Ordinary Portland cement is the most commonly used building

material throughout the world and it will retain its status in near future

also because of demand and expansion of construction industry all

over the world. Further the greatest challenge before the concrete

construction industry is to serve the two pressing needs of human

society, namely the protection of environment and meeting the

infrastructure requirements of our growing population Structures

which are constructed in aggressive environments are liable to be

subjected to acidic attack. One of such major problems is HCL attack

against concrete structures due to which there will be loss of weight

and reduction in strength of concrete ultimately sacrificing age of the

structure. Contaminated ground water, seawater, industrial effluents

are some of the sources of sulphate that attack concrete. The use of

blended cements have shown a sharp results in resisting the sulphate

attack on concrete, sugarcane bagasse ash which shows pozzolanic

properties is being used as a partial replacement in concrete in regular

5
intervals of 5% up to 25%. SCBA is being produced from sugar

manufacturing units as a waste material which will be grinded to the

fineness less than cement for obtaining good bonding between cement

and SCBA. This project discusses the very severe exposure of HCL

on concrete.

ORDINARY PORTLAND CEMENT (OPC):

Ordinary Portland cement is a controlled blend of calcium silicates,

aluminates and ferrate, which is ground to a fine powder with gypsum

and other materials. After 1987 OPC was divided into 3 types based

on the strength obtained at 28 days

1. OPC 33 grade:-strength not less than 33N/mm2 at 28 days

2. OPC 43 grade:-strength not less than 43N/mm2 at 28 days

3. OPC 53 grade:-strength not less than 53N/mm2 at 28 days

Portland cement gets its strength from chemical reactions between the

cement and water. The process is known as hydration. This is a

complex process that is best understood by first understanding the

chemical composition of cement.

6
 CHEMICAL COMPOSITION OF CEMENT:

COMPOUND FORMULA MASS%

Calcium oxide CaO 61-67%
Silicon dioxide SiO2 19-23%
Aluminium oxide Al2O3 2.5-6%

Iron oxide Fe2O3 0-6%

Sulphate SO3 1.5-4.5%

CHEMICAL COMPOSITION OF CLINKER:

COMPOUND FORMULA MASS%

Tricalcium silicate (CaO)3 · SiO2 45–75%

Dicalcium silicate (CaO)2 · SiO2 7–32%

Tricalcium aluminate (CaO)3 · Al2O3 0–13%

Tetra calcium (CaO)4 · Al2O3 ·Fe2O3 0–18%

aluminoferrite
Gypsum CaSO4 · 2 H2O 2–10%

7
INTRODUCTION TO CEMENT CONCRETE:

An artificially built up stone resulting from hardening of a

mixture of a cement, aggregates and water with or without a suitable

admixture, is generally known as concrete.

Cement concrete is a mixture of aggregates and cement water

paste. The cement water paste has its role to bind the aggregates to

form a strong rock like mass after hardening has a consequence of the

chemical reaction between cement and water. Aggregates are

classified into fine aggregate and coarse aggregate. Fine aggregate

consist of sand whose particular size does not exceed 4.75mm coarse

aggregate consist of gravel, crush stone etc. of practical size more

than 4.75mm.

When the materials are mixed together so has to form a

workable concrete, it can be moulded into beams, slabs etc. A few

hours after mixing the material undergo a chemical combination and

have a consequence the mixture solidifies and hardness, attaining

8
greater strength with age. Concrete possess a high compressive

strength and has a poor tensile strength. It also develops shrinkage

stresses.

PROPERTIES OF CONCRETE:

A hardened concrete must possess the following properties:

1) Strength: Strength is defined as the resistance of the hardened

concrete to rupture under different loadings and is accordingly

designated in different - i.e., tensile strength, compressive strength,

flexural strength, etc. A good quality concrete in hardened - must

possess the desired crushing strength.

2) Durability: Durability is defined as the period of time up to which

concrete in hardened - withstands the weathering effects satisfactorily.

This property is mainly affected by water cement ratio. A good quality

concrete in hardened state must be durable.

3) Impermeability: The impermeability of hardened concrete may

be defined as the property to resist entry & water. This property is

9
achieved by using extra quantity of cement in concrete mix. A

concrete in hardened state must be impermeable.

4) Elasticity: Though hardened con- is a brittle material, it is desired

that it possess adequate elasticity.

5) Shrinkage: A hardened concrete should experience least shrinkage.

This property is guided by water cement ratio. Shrinkage is less if w/c

ratio is less.

SCOPE OF THE WORK:

The of the present work is to carry out a detailed analysis of the

following sub-systems for the prescribed conditions

1. Concrete mix design for M30grade of concrete

2. Casting of concrete cubes of M30 grade of concrete with different

percentages of SUGARCANE BAGASSE ASH (0%, 5%, 10%, 15%,

20%, 25%).

3. Cubes are subjected to normal & HCL curing.

10
4. Testing of specimens at various ages.

5. Plotting graphs and comparing the compressive strengths of

sugarcane bagasse ash blended concrete cubes in normal and HCL

curing.

SUGARCANE BAGASSE ASH:-

Bagasse is a by-product from sugar industries which is burnt to

generate power required for different activities in the factory. The

burning of bagasse leaves bagasse ash as a waste, which has a

pozzolanic property that would potentially be used as a cement

replacement material. It has been known that the worldwide total

production of sugarcane is over 1500 million tons.

Sugarcane consists about 30% bagasse whereas the sugar recovered is

about 10%, and the bagasse leaves about 8% bagasse ash (this figure

depend on the quality and type of the boiler, modern boiler release

lower amount of bagasse ash) as a waste, this disposal of bagasse ash

will be of serious concern.

Sugarcane bagasse ash has recently been tested in some parts of the
11
world for its use as a cement replacement material. The bagasse ash

was found to improve some properties of the paste, mortar and

concrete including compressive strength and water tightness in certain

replacement percentages and fineness.

The higher silica content in the bagasse ash was suggested to

be the main cause for these improvements. Although the silicate

content may vary from ash to ash depending on the burning conditions

and other properties of the raw materials including the soil on which

the sugarcane is grown, it has been reported that the silicate undergoes

a pozzolanic reaction with the hydration products of the cement and

results in a reduction of the free lime in the concrete.

HCL ATTACK:

The chemicals formed as the products of reaction between

hydrochloric acid and hydrated cement phases are some soluble salts

and some insoluble salts. Soluble salts, mostly with calcium, are

subsequently leached out, whereas insoluble salts along with

amorphous hydrogels, remain in the corroded layer. Besides

12
dissolution, the interaction between hydrogels may also result in the

formation of some Fe-Si, Al-Si, Ca-Al-Si complexes which appear to

be stable in pH range above 3.5.

Ca(OH)2 + 2HCl  CaCl2 + 2H2O

The reaction essentially causes leaching of Ca(OH)2 from the set

cement.

After leaching out of Ca(OH)2, C-S-H and ettringite start to

decompose, with release of Ca2+ to counteract the loss in Ca(OH) 2 and

the set cement starts to disintegrate accelerating the dissolution.

Ca6Al2(SO4)3(OH)12.26H2O  3Ca2+ +2[Al(OH)4]- +4OH- +26H2O

3Ca2+ +2[Al (OH)4]- +4OH- +12HCL  3CaCl2 + 2ALCL3 + 12H2O

There are few indications through experiments about the formation of

Friedel’s salt, C3A.CaCl2.10H2O, by the action of CaCl2, formed due

to reaction of HCL with CH and C3A

13
Hydrochloric acid attack is a typical acidic corrosion which can be

characterized by the formation of layer structure.

By hydroxide mixture zone a layer is formed by undissolved salts

seen as a dark brown ring.

PHYSICAL Properties of Hydrochloric acid:

Properties of Hydrochloric Acid

Molecular formula HCL in water (H2O)
Molar mass 36.46 g/mol (HCL)
Appearance Clear colourless to light-yellow liquid
Density 1.18g/cm3
Melting point 27.32 °C (247 K)
Boiling point 110 °C (383 K)
Solubility in water Miscible
Acidity (pKa) −8.0
Viscosity 1.9 mPa·s at 25 °C,

14
LITERATURE REVIEW

15
[Link] Sekhar Reddy, [Link] Reddy, December 2012 studied

the behaviour of High Performance Concrete (HPC) which is being

the most used type of concrete in the construction industry. They

replaced cement with Supplementary cementing materials (SCM) like

fly ash, silica fume and metakaolin. The mix design adopted was M 60,

cubes were casted and cured for 90 days in 5% HCL(P H=2), NaOH,

MgSo4 and Na2So4

They concluded that there was a considerable increase in

service life of the concrete structures and reduction in heat of

hydration by using the supplementary cementing materials in

concrete. They observed the maximum and minimum percentage of

reduction in strength of concrete when concrete was replaced with fly

ash were 12.64% and 1.92%.

Dr. P. Srinivasa Raoetal., studied the durability characteristics of

metakaolin blended concrete by adopting M 20 grade of concrete. An

attempt was made with H2So4 and HCL. Steel fibres with 60 as aspect

ratio at 0%, 0.5%, 1.0%, and 1.5% of volume of concrete are used.

16
 They concluded that the percentage weight loss was reduced

and compressive strength was increased in the case of fibre reinforced

concrete and concrete containing 10% metakaolin replaced by weight

of cement when compared to concrete and the percentage weight loss

was less when immersed in HCL and H2So4.

P. Murthi and V. Siva Kumar 2008 studied the resistance of

acid attack of ternary blended concrete by immersing the cubes for 32

weeks in sulphuric acid and hydrochloric acid solutions. Binary

blended concrete was developed using 20% class F fly ash and ternary

blended concrete was developed using 20% fly ash and 8% silica

fume by weight of cement.

They concluded that the ternary blended concrete was

performing better that the ordinary plain concrete and binary blended

concrete. They observed that the mass loss for 28 and 90 days of M20

PCC specimens were 19.6% and 16.1% respectively. They also

observed that the time taken for reduction of 10% mass loss when

immersed in 5% H2So4 and 5% HCL solutions was 32 weeks.

17
A.K. Al-Tamimi and M. Sonebi studied the properties of Self-

Compacting Concrete when immersed in acidic solutions. Workability

was obtained using slump cone test, L-box and orimet for SCC mix.

Cylindrical specimens of diameter 45mm and length 90mm were

casted and cured for 28 days in water after they were immersed in 1%

HCL and 1% H2So4 solutions by maintaining a pH of 5 regularly.

They conclude that self-compacting concrete was performing

better than control concrete when exposed to 1% sulphuric acid and

hydrochloric acid. They observed that the time taken for 10% mass

loss for SCC was 18 weeks and for CC was 6 weeks.

[Link] Reddy et al., studied the effect of HCL on blended

cement (fly ash) and silica fume blended cement and their concretes.

Concrete cubes were casted using deionised water with a series of

dosages (100, 150, 300, 500 and 900 mg/l) implanted into water and

using only deionised water for comparison. These cubes were tested

for determining chloride ion permeability (RCPT) and compressive

strength

18
 They concluded that the compressive strengths reduction of

flyash blended concrete and silica fume blended concrete was 2to

19% at 28 and 90 days.

Beulah M. Asst Professor, Prahallada M. C. Professor studied the

effect of replacement of cement by metakaolin in high performance

concrete subjected to HCL attack. Cubes were casted with different

water cement ratios (0.3, 0.35, 0.4 and 0.45), compressive strength

was evaluated for 150×150×150 mm cubes and percentage weight

loss was evaluated for 100×100×100 mm cubes. These cubes were

cured for 30, 60 and 90 days in 5% hydrochloric acid.

They concluded that the residual compressive strength after 30,

60 and 90 days of immersion decreases with increasing water binder

ratio which is due to porous transition zone leading to the formation of

ettringite at higher water levels.

Urooj Masood et al., studied the behaviour of mixed fibre reinforced

concrete exposed to acids. A mixture 75% glass and 25% steel fibres

were used in mixed fibre reinforced concrete and cubes were casted

19
and cured for 7, 14, 28days in acids and sodium sulphate. Test

specimens were tested for weight loss and denseness of concrete of

exposed and unexposed specimens at all the ages and compressive

strength at 180 days.

They concluded that the resistance towards the sulphuric acid

attack was maximum when 100% steel fibres was used when

compared to other fibres and without any fibres. Mixed fibre

reinforced specimens and 100% steel fibre reinforced specimens

exhibited more resistance towards the attack of sulphuric acid.

Mr. G. Siva Kumar et al., (2013) had studied on “Preparation of Bio-

cement using Sugarcane bagasse ash and its Hydration behaviour”. In

this study they had used as partial Replacement in ordinary Portland

Cement (OPC) by 10% weight. Compressive strength of the sample

was carried out and reported that the cementious material in sugar

cane bagasse ash is responsible for early hydration. The pozzolanic

activity of bagasse ash results in formation of more amount of C-S-H

20
gel which results in enhances the strength, and hence bagasse ash is a

potential replacement material for cement.

Mr. H.S. Otuoze et al., had investigated on “Characterization of Sugar

Cane Bagasse ash and ordinary Portland Cement blends in Concrete” ,

The SCBA is obtained by burning Sugar cane Bagasse at between

600-700 degrees Celsius, since the sum of Sio2, Al2o3 and Fe2o3 is

74.44%, For strength test , mix ratio of 1:2:4 was used and OPC was

partially replaced with 0% ,5%, 10%, 15%, 20%, 25%, 30%, 35%,

40% by weight in concrete. Compressive strength values of hardend

concrete were obtained at the ages of 7,14,21,28 days. Based on the

test conducted, it can be concluded that SCBA is a good pozzolana for

concrete cementation and partial blends of it with OPC could give

good strength development and other engineering properties in

concrete. An optimum of 10% SCBA blends with OPC could be used

for reinforced concrete with dense aggregate. Higher blends of 15%

and up to 35% of SCBA with OPC are acceptable for plane or mass

concrete. The value fell short of meeting requirements for reinforced

21
concrete with dense aggregate because of excessive fines from

increasing SCBA and reducing Strength of bonding.

Mr. Lavanya M.R et al., had studied on “A Experimental Study on

the Compressive Strength of Concrete by Partial replacement of

Cement with Sugar cane bagasse ash”. The Feasibility of using sugar

cane bagasse ash, a finely grounded waste product from the

sugarcane industry, as partial replacement for cement in conventional

concrete is examined. The test were conducted as per Bureau of

Indian Standard (BIS) codes to evaluate the stability of SCBA for

partial replacement up to 30% of cement with varying water cement

(W/C) ratio. They showed that addition of SCBA results in

improvement of strength in all cases and according o the results

obtained, it can be concluded that Bagasse ash can increase the overall

strength of concrete when used up to a 15% cement replacement level

with W/C ratio of 0.35, bagasse ash is a valuable pozzolanic material

and it can potentially be used as a partial replacement for cement.

22
Mr. R. Srinivasan et al., has investigated on “Experimental Study on

Bagasse Ash in Concrete”. They had observed that Sugar Cane

bagasse is fibrous waste-Product of sugar refining industry, and

causing serious environmental problem which mainly contain

aluminium ion and silica. Hear bagasse ash has been chemically and

physically characterized, and partially replaced in the ratio of 0%, 5%,

15%, 25% by weight of cement in concrete. Fresh concrete tests like

compaction factor test and slump cone test were undertaken, was well

as hardened concrete test like compressive strength , split tensile

strength, flexural strength and modulus of elasticity at the age of

seven and 28 days was don. The results show that the SCBA in

blended concrete had significantly higher compressive strength,

tensile strength, and flexural strength compare to that of the concrete

without SCBA. It is found that cement could be advantageously

replaced with SCBA up to maximum limit of 10%. Partial

replacement of cement by SCBA increases workability of fresh

23
concrete; therefore use of super plasticizer is not substantial. The

density of concrete decreases with increase in SCBA content.

Mr. U.R. Kawade et al., had studied on “Effect of use of Bagasse ash

on Strength of Concrete” they had Chemically and Physically

Characterized and partial replaced in the ratio of 0%, 10%, 15%, 20%,

by weight of cement in concrete. The results show that the SCBA

concrete had significantly higher compressive strength compared to

that of the concrete without SCBA. It is found that the cement could

be advantageously replaced with SCBA up to maximum limit of 15%.

Although the optimal level of SCBA content was achieved with 15%

replacement. Partial replacement of cement by SCBA increases

workability of fresh concrete, therefore use of Super Plasticizer is not

essential.

Lourdes M. S. Souza et al., had studied on “Hydration Study of Sugar

Cane Bagasse Ash and Calcium Hydroxide Pastes of Various Initial

C/S Ratio” they had investigated on the reactions between calcium

hydroxide (CH) and sugar cane bagasse ash (SCBA). For this purpose,
24
pastes of various initial CaO/SiO2 (C/S) molar ratios were produced.

The formed products were analyzed by thermal analyses, X-ray

diffraction, scanning electron microscopy and energy dispersive

spectrometer. The results show that the main product was found to be

C-S-H of not specific morphology and that could not be related to the

known products C-S-H (I)/C-S-H (II). Calcium alumina silicate

hydrates and calcium aluminate hydrate, in the form of fine plates or

needles, were also produced. The main product formed in the

pozzolanic reactions between SCBA and CH is C-S-H and it appears

as a dense net of amorphous agglomerations. In addition, it cannot be

correlated with the C-S-H formed in the reaction of hydrous silica and

CH. C2ASH8, C4AH13 and C3ASH6 are also formed and they appear as

thin places or needles deposited inside the pores of the C-S-H net.

Piyanut Muangtong et al., had investigated on “Effects of Fine

Bagasse Ash on the Workability and Compressive Strength of

Mortars” They are currently exploited as pozzolanic materials and

supplements to improve the compressive strength in terms of

25
microstructures of cement by partly replacement of cement with them.

One of their advantages is to decrease CO2 gas emission from

decreasing consumption of cement in either mortar or concrete

production. Appropriate ratio of replacing clinker by fine (<45

micron) SCBA and w/c ratio as well as effects of SCBA on properties

of cement are being studied in this research. Initially, clinker and

SCBA proportion were designed by replacing clinker with the amount

of SCBA at 0, 20 and 40%, respectively, whereas gypsum was

constant added. Specimens were casted as cement mortars and pastes

and, finally, analysed for compressive strength, flow ability, chemical

composition and microstructure according to curing ages of 3, 7 and

28 days. Their properties were carried out and compared with the

results of commercial type I Portland cement. These test results

indicated that replacing clinker with 20% SCBA was appropriate for

production in laboratory scale and w/c ratio of 0.735 is suitable on

workability of the resultant cement. The results of this research

indicated that the appropriate proportion of clinker replaced by fine

26
bagasse ash was 20% SCBA (C80B20). It presented the highest

compressive strength comparing to all ratios (0-40% SCBA) of

resultant cements and near that of commercial cement. The

appropriate w/c ratio of C80B20 was 0.735:1 for good mortar flow

(110±5%) and workability of cement mortar. It was ensured that

increasing amount of SCBA influenced the increase of w/c ratio.

Moreover, this cement procedure was possible for cement preparation

in laboratory and would lead to industrial production in the future.

Asma Abd Elhameed Hussein et al., had studied on “Compressive

Strength and Microstructure of Sugar Cane Bagasse Ash Concrete”

This study presents the results of an experimental research study on

the effectiveness of Sugar Cane Bagasse Ash (SCBA) as a cement

replacement material in concrete production. The ordinary Portland

cement was replaced with 0, 5, 10, 15 respectively bagasse ash, the

effect of Sugar cane Bagasse Ash on workability, compressive

strength and microstructure of Interfacial Transition Zone (ITZ) of

concrete was examined. The results showed that

27
inclusion of Sugar cane Bagasse Ash in concrete up to 20% level

significantly enhanced the compressive strength of concrete at all

ages; the highest compressive strength was obtained at 5% SCBA

replacement level. The ITZ thickness was greatly reduced with

increasing the bagasse ash replacement level up to 15%, beyond that

the ITZ thickness was slightly increased, however the thickness was

still narrower than the normal concrete, it was observed that at 15%

bagasse ash replacement level, the interfacial transition zone was

homogeneous and there was no gap between the coarse aggregate and

the paste matrix. From this study they had observed that linearly

increase the workability of concrete.

Up to 20% replacement enhanced both the compressive strength

at all ages. Highest 28-day compressive strength was obtained using

5% SCBA replacement which was about 48% higher than the

reference mix-up to 20% SCBA in concrete is considered as the

optimum replacement level.

28
Twenty five and thirty percent SCBA improved the compressive

strength after 28 days. Inclusion of SCBA in concrete up to 30%

significantly improved the microstructure of concrete by reducing the

ITZ thickness which indicates better refinement of pore structure and

dense matrix compared to the reference mix.

At 15% SCBA level the microstructure of ITZ was totally

homogeneous without the presence of wall effect between the

aggregate and the paste matrix.

The micro structural properties are strongly related to the compressive

strength of concrete. Further studies on microstructure of ITZ for

SCBA concrete are needed as there is no available literature and it is

first introduced in this study.

Kanchana lata Sigh and S.M Ali Jawaid, had studied on “utilization

of sugarcane Bagasse ash (SCBA) as Pozzolanic Material in concrete”

Agricultural and industrial by-products are commonly used in concrete

production as cement replacement materials CRMs or as admixtures to

enhance both fresh and hardened properties of concrete as well as to

29
save the environment from the negative effects caused by their

disposal. Approximately 1500 Million tons of sugarcane is annually

produced over all the world which leave about 40-45 % bagasse after

juice crushing for sugar industry giving an average annual production

of 675 Million tons of bagasse as a waste material. This paper

examined the potential of bagasse ash for development as pozzolanic

materials in concrete. The bagasse ash is a by-product from the

combustion of bagasse as a fuel in thermal power plants and sugar cane

industries. This paper presents a review on the uses of sugarcane

bagasse ash in concrete. From review it may be concluded that

Sugarcane Bagasse ash can be used as a pozzolanic material in

concrete due to its high silica content. The results of this research

indicated (10% sugarcane bagasse ash) in blended concrete had

significantly higher compressive strength, as compare to 20%

sugarcane bagasse ash. Sugarcane bagasse ash is pozzolanic material

which may be utilized in the production of pozzolanic cement concrete

which leads to reduction in cost.

30
METHODOLOGY

31
 LITERATURE REVIEW

Material Collection

Material Investigation

Mix Design

Replacement of Sugarcane Bagasse Ash

in Concrete

Test Conducted

32
EXPERIMENTAL

INVESTIGATION

33
INTRODUCTION

In the present experimental investigation sugar cane bagasse ash has been

used as partial replacement of cement in concrete mixes. On replacing cement

with different weight percentage of SCBA the compressive strength is studied at

different ages of concrete cured in different environments like normal water and

HCL diluted solution. The details of experimental investigations are as follows.

MATERIALS USED

CEMENT

Ordinary Portland cement of 53 grades from a single batch was used for the

entire work and care has been taken that it has to been stored in airtight containers

to prevent it from being affected by the atmospheric and monsoon moisture and

humidity. The cement procured was tested for physical requirements in

accordance with IS: 12269-1987 and for chemical requirements in accordance

with IS: 4032-1977.

34
Properties of cement:

S. No Property Value
1. Normal consistency 33mm
2. Fineness of cement 7%

Setting time
3.

Initial (Minutes) 85

Final (Minutes) 240

Compressive Strength

4.

7 Days 28.68 Mpa

14 Days 40.34 Mpa

28 Days 54.62 Mpa

35
SUGARCANE BAGASSE ASH

Sugarcane bagasse consists of approximately 50% of cellulose, 25% of

hemicelluloses of ligin. Each ton of sugarcane generates approximately 26% of

bagasse (at a moisture content of 50%) and 0.62% of residual ash. The residue

after combustion presents a chemical composition dominates by silicon dioxide

(sio2). In spite of being a material of hard degradation and that presents few

nutrients, the ash is used on the farms as a fertilizer in the sugarcane harvests. In

this sugarcane bagasse ash was collected during the cleaning operation of a boiler

in the sugar factory, located in the town of Perambalur, Tamil Nadu.

36
Physical Properties of SCBA:

S. No. Property Value

1. Density 575Kg/m3

2. Specific Gravity 2.2

3. Mean particle size 0.1-0.2 µm

Min specific 2500m2/ kg

4. surface area

5. Particle shape Spherical

37
 Chemical Properties of SCBA:

S No Component Symbol Percentage

1. Silica SiO2 63
2. Alumina Al2O3 31.5
3. Ferric Oxide Fe2O3 1.79
4. Manganese Oxide MnO 0.004
5. Calcium Oxide C aO 0.48
6. Magnesium Oxide MgO 0.39

7. Loss on Ignition LOI 0.71

FINE AGGREGATE

The river sand, passing through 4.75 mm sieve and retained on 600 μm sieve,

conforming to Zone II as per IS 383-1970 was used as fine aggregate in the

present study. The sand is free from clay, silt and organic impurities. The

aggregate was tested for its physical requirements such as gradation, fineness

modulus, specific gravity and bulk modulus in accordance with IS: 2386-1963.

38
Properties of fine aggregate:

[Link]. Property Value

1. Specific 2.60
Gravity
2. Bulk density 1.542
gm/cc

3. Fineness 2.74
Modulus
4. Zone II

COARSE AGGREGATE

Throughout the investigations, crushed coarse aggregates of

20mm procured from the local crushing plants were used. The aggregate was

tested for its physical requirements such as gradation, fineness modulus, specific

gravity and bulk density [Link] accordance with IS: 2386-1963 and IS: 383-1970.

39
Properties of coarse aggregate:

S. No. Property Value

1. Bulking Density ()

gm/cc
1.610

2. Specific Gravity 2.74

(G)(20mm)

7.17
3. Fineness Modulus

4. Aggregate impact Value (%) 25.21

5. Aggregate crushing Value (%) 25.22

40
WATER

Fresh portable water free from organic matter and oil is used in mixing the

concrete. Water in required quantities were measured by graduated jar and added

to the concrete. The rest of the material for preparation of the concrete mix was

taken by weigh batching. The pH value should not be less than 7.

PREPARATION OF TESTING SPECIMEN

MIXING

Mixing of ingredients is done in pan mixer of capacity 40 liters. The cementitious

materials are thoroughly blended and then the aggregate is added and mixed

followed by gradual addition of water and mixing. Wet mixing is done until a

mixture of uniform colour and consistency are achieved which is then ready for

casting. Before casting the specimens, workability of the mixes was found by

compaction factor test.

41
PREPARATION OF SPECIMENS

The cast iron moulds are cleaned of dust particles with mineral oil on all

sides before concrete is poured in to the moulds. The moulds are and applied

placed on a level platform. The well mixed concrete is filled in to the moulds and

kept on vibration table. Excess concrete was removed with trowel and top surface

is finished level and smooth as per IS 516-1969.

CURING OF THE SPECIMENS

The specimens are left in the moulds undisturbed at room temperature for

about 24 hours after casting. The specimens are then removed from the moulds

and immediately transferred to the different curing environment tubs i.e. cubes are

cured in fresh water.

42
TESTING OF SPECIMENS

A time schedule for testing of specimens is maintained to ensure their

proper testing on the due date and time. The cast specimens are tested as per

standard procedures, immediately after they are removed from curing tubs and

wiped off the surface water, as per IS 516-1959.

Hydraulic Compressive Testing Machine

43
DESCRIPTION OF COMPRESSION TESTING MACHINE

The compression testing machine used for testing the cube specimens is of

standard make. The capacity of the testing machine is 2000 KN. The machine

has a facility to control the rate of loading with a control valve .The plates are

cleaned and oil level is checked, and kept ready in all respects for testing.

After the required period of curing, the cube specimens are removed from the

curing tubs and cleaned to wipe off the surface water. It is placed on the machine

such that the load is applied centrally. The smooth surfaces of the specimen are

placed on the bearing surfaces. The top plate is bought in contact with the

specimen by rotating the handle. The oil pressure valve is closed and the machine

is switched on. A uniform rate of loading 140 kg/[Link]/min is maintained.

TESTS CONDUCTED

WORKABILITY

The workability was measured using slump cone and compaction factor

apparatus for different percentage replacement of cement with sugarcane bagasse

ash in concrete.

44
COMPRESSIVE STRENGTH OF CONCRETE SPECIMENS

Concrete specimens are casted to determine the compressive strength of

different weight percentages of sugarcane bagasse ash concrete as per IS 516-

1969.

DURABILITY

The durability of sugarcane bagasse ash concrete was tested for resistance

10ml HCL diluted solution. The response of chemical attack on different

percentage replacement of cement with sugarcane bagasse ash in concrete was

studied by reduction in compressive strength. For conducting these tests, concrete

cubes of 150mm x 150mm x 150mm size with ordinary and different percentage

replacement of cement with sugarcane bagasse ash were cast. These cubes were

immersed in a HCL solution by maintaining 4 to 4.5 ph values for different

periods of 7, 14 and 28days.

Durability studies on Cement Conventional Concrete & Sugar Cane Bagasse

Ash Concrete

Concrete is the most versatile material of construction the world over. It is

achieved that the distinction of being the “largest man-made material” with the

average per capita consumption exceeding 2 kg. Concrete is the material of choice

for a variety of applications such as housing, bridges, highway pavements,

industrial structures, water carrying and retaining structures etc. The credit for this
45
achievement goes to well-known advantages of concrete such as easy availability

of ingredients, adequate engineering properties for a variety of structural

applications, adaptability, versatility, relative low-cost etc. Moreover, concrete has

an excellent ecological profile compared with other materials of construction.

With the continuing expansion of infrastructure and housing construction,

especially in the developing countries of Asia, Africa, and South America, the rate

of consumption of cement and concrete is rising and is bound to go further. In

India, concrete construction scenario has been witnessing considerable growth in

recent years.

46
Standard sieves

A) Sieve Analysis

Table I : Sieve analysis of Coarse Aggregate

S .No. I.S. Sieve Weight Percentage weight Cumulative Percentage

No. retained
Retained (gms) Percentage Passing
Retained

1. 40mm 0 0 0 100

2. 20mm 877 17.54 17.54 82.46

3. 10mm 4085 81.70 99.24 0.76
4. 4.75mm 38 0.76 100.00 0
5. 2.36mm 0 0 100.00 0
6. 1.18mm 0 0 100.00 0
7. 600µ 0 0 100.00 0
8. 300µ 0 0 100.00 0
9. 150µ 0 0 100.00 0
Total : 716.78

Fineness modulus = 716.78 / 100 = 7.17

47
Table II : Sieve Analysis of Fine Aggregate

S. No. I.S. Sieve No. Weight retained Percentage Cumulative Percentage

weight percentage passing
(gm) retained retained

1. 40mm 0 0 0 100
2. 20mm 0 0 0 100

3. 10mm 0 0 0 100
4. 4.75mm 21 2.10 2.10 97.90

5. 2.36mm 65 6.50 8.60 91.40

6. 1.18mm 180 18.00 26.06 73.94
7. 600µ 278 27.80 54.04 45.96
8. 300µ 280 28.00 82.04 17.96
9. 150µ 176 17.06 100.00 0
Total : 274.00

Fineness modulus of sand = 274.1 /100 = 2.74

Confirming to zone II (I.S.: 383-1970)

Table III : Physical Properties of Fine and Coarse Aggregate

Test results
S. No. Properties
Fine Aggregate Coarse Aggregate

1. Specific gravity 2.60 2.74

Bulk Density (Kg/m3)

2. a) loose 1600 kg/m3 1400 Kg/m3

b) compacted 1750 kg/m3 1580 Kg/m3

3. Fineness Modulus 2.74 7.17

48
 0% 5% 10% 15% 20%
Slump 10mm 13mm 16mm 20mm 25mm
Table IV- Workability of concrete

From the test conducted are Sieve analysis on coarse aggregate and fine

aggregate, the fineness modulus is 7.17 (from Table-10) for coarse aggregate. This

should be between 6.5 to 8, and as Zone-II sand is used, the fineness modulus of

fine aggregate is 2.54(Table-11), this should be in a range of 2.2 to 2.6 as per

IS383. And we observed a varying slump value as the Percentage of Sugarcane

bagasse ash increases. There is increase in slump value as percentage of

Sugarcane bagasse ash increases, Table-13 shows you the increase in slump value

as sugarcane bagasse ash increases (i.e 0%-10mm, 5%- 13mm etc.).

49
MIX PROPORTION

50
 DESIGN OF MIX CONCRETE(M25)

Aggregate size : 20mm

Minimum cement content: 320 kg/m3(from table 5 IS 456)

w/c ratio: 0.45(IS:456; Table-5)

workability: 100mm (slump)

Exposure: Severe

51
1) Target Mean Strength of concrete

From IS: 10262-2019, the target mean strength for the specified

characteristic cube strength is

= ƒck + 1.65 s

Then = 25 + (4 1.65) = 31.6 N/mm2

('s' is standard deviation N/mm2 s =4, from table 1 IS 10262:2019)

2) Selection of Water-Cement Ratio

The free Water Cement ratio required for the target mean strength of 31.6

N/mm2 is W/C =0.45.

3) Selection of water content:

for 20mm aggregate = 186 kg ( 50mm slump)

for 25mm slump = 186 - 10% of 186 (for every 25mm increase in slump 3%

water should be increased)

167.4kg (from table 2 IS 10262-cl.5.3)

4) Determination of Cement content:

w/c = 0.45

167.4/c = 0.45

c = 372kg/m3>300kg/m3 hence ok

52
5) Proportion of volume of coarse aggregate and fine aggregate content:

Fine aggregate = Zone 2

volume of coarse aggregate per unit volume of total aggregate for different

zones of fine aggregate = 0.62 (from table 3 IS 10262:2019)

when w/c = 0.5 = 0.62 for every +/- 0.05 change in w/c ratio we have to

change -/+ 0.01 change in volume of coarse aggregate per unit volume of total

aggregate

therefore Volume of coarse aggregate = 0.62

Fine aggregate=1- 0.62 = 0.38

6) Mix calculations:

a) volume of concrete = 1m3

take cement content = 372kg/m3

b) Volume of cement = (mass of cement/specific gravity)*(1/1000)

= 372/(3.15*1000) = 0.118m3

c) Volume of water = (mass of water/specific gravity)*(1/1000)

= 167.4/(1.0*1000) = 0.1674m3

d) Volume of aggregate = 1-(b+c+d)

= 1-(0.125+0.00386) = 0.686m3

53
e) Mass of coarse aggregate = d* volume of coarse aggregate*specific gravity of

coarse aggregate = (0.713*0.549*1000) = 1147 kg

f) Mass of fine aggregate = d* volume of fine aggregate*specific gravity of fine

aggregate = (0.713*0.451*2.46*1000) = 691kg

The mix proportion then becomes:

Mix proportions for M25 by weight

Water : Cement : Fine Aggregate : Coarse Aggregate

167.4 : 372 : 691 : 1147

0.45 : 1 : 1.86 : 3.08

54
RESULTS AND DISCUSSIONS

55
RESULTS AND DISCUSSIONS:

Compressive strength Results – M30 grade at Normal water & HCL

Solutions

Table V: Compressive Strength Results (M25 in normal water)

Sample % Replacement of compressive compressive compressiv

Designation SCBA in Cement strength strength e strength
at 7 days at 14 days at 28days
(σcu) (σcu) (σcu)
C0 0 29.17 37.5 42.82

C1 5 32.5 40.6 41.33

C3 10 32.92 43.58 43.75

C4 15 29.58 40.42 42.22

C5 20 26.38 37.36 37.92

C6 25 27.36 36.38 33.58

Table VI: Compressive Strength Results (M25 in HCL)

Sample % Replacement of compressive compressive compressive

Designation SCBA in Cement strength strength strength
at 7 days at 14 days at 28days
(σcu) (σcu) (σcu)
C0 0 27.08 35.42 37.5

C1 5 31.11 36.25 38.75

C3 10 32.5 42.78 40.13

C4 15 27.63 33.75 36.67

C5 20 26.38 33.33 32.92

C6 25 16.8 25.55 21.67

56
 Results of Durability Studies

Table VII: Reduction in Compressive strength under HCL attacking for 7 days

Sample % Replacement
Designation of SCBA in (σcu) (σ1cu) % decrease
Cement in strength
M0 0 29.17 27.08 7.14

M1 5 32.5 31.11 4.28

M2 10 32.92 32.5 2.53

M3 15 29.58 27.63 7.4

M4 20 26.38 26.38 3.1

M5 25 27.36 16.8 38.5

Table VIII: Reduction in Compressive strength under HCL attacking for 14

days

Sample % Replacement
Designation of SCBA in (σcu) (σ1cu) % decrease
Cement in strength
M0 0 37.5 35.42 5.55

M1 5 40.6 36.25 10.8

M2 10 43.58 42.78 1.8

M3 15 40.42 33.75 16.49

M4 20 37.36 33.33 4.8

M5 25 36.38 25.55 13

57
 Table IX: Reduction in Compressive strength under HCL attacking for 28 days

Sample % Replacement
Designation of SCBA in (σcu) (σ1cu) % decrease
Cement in strength
M0 0 42.82 37.5 6.38

M1 5 41.33 38.75 3.1

M2 10 43.75 40.13 4.34

M3 15 42.22 36.67 6.66

M4 20 37.92 32.92 6

M5 25 33.58 21.67 14.33

GRAPHS:

4
5

4
0
[Link], N/mm2

3
5

3 M25(WATER
0 )
2 M25(HCL)
5

2
0

1 0% 5% 10% 15% 20% 25%

% replacement

Graph 1: Compression test results for 7 days in normal water & HCL Solution

58
 60

[Link], N/mm2
50

40

30
M25(WATER)
20 M25(HCL)

10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 2: Compression test results for 14 days in normal water & HCL Solution

60

50
[Link], N/mm2

40

30
M25(WATER)
20 M25(HCL)

10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 3: Compression test results for 28 days in normal water & Hcl Solution

59
 60

50

[Link] N/mm2
40

30 7 days
14 days
20
28 days
10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 4: Compression test results for 7, 14 & 28 days in normal water

60

50
[Link] N/mm2

40

30 7 days
14 days
20
28 days
10

0
0% 5% 10% 15% 20% 25%
% replacement

Graph 5: Compression test results for 7, 14 & 28 days in HCL Solution

60
As the percentage of sugarcane bagasse ash increases the compressive strength of

concrete tends to increase up to certain percentage and then start’s decreasing with

the increase of ash content.

The strength of 10% sugarcane bagasse ash concrete is more than 5% sugar cane

bagasse ash concrete and strength of 5% sugar cane bagasse ash concrete is more

than normal concrete. This shows that till 10% sugarcane bagasse ash concrete the

strength increases while percentage of sugarcane bagasse ash increases.

The strength of cubes having 10% sugar cane bagasse ash is almost equal to 15%

sugar cane bagasse ash concrete.

This increase in strength in Sugar cane bagasse ash concrete is due to presence of

Silica in Sugar cane bagasse ash. Silica in Sugar cane bagasse ash react with

residual CH after the formation of C-S-H gel, and increase the amount of C-S-H

gel and results in increase the strength.

61
SPLIT TENSILE TEST

The Cylinder models of size 150 mm x 300 mm were placed evenly between

the stacking surface of the Compression Testing Machine of 2000KN Capacity and

the test was Carried out as per IS:5816-1999. The load was applied gradually. The

increase in split tensile strength for various test specimens was observed.

The Split tensile strength can be calculated by,

Split Tensile Strength (N/mm2 ¿ = 2P/ πDL

Where L = Length of the specimen in mm

D = Diameter of the specimen in mm

P = Maximum load in N

Table X: Split Tensile Strength Results

No. of 0% 5% 10% 15% 20% 25%

Days

7 days 2.0 1.9 2.1 1.75 1.6 1.3

14 days 2.15 2.3 2.5 1.85 1.7 1.4

28 days 2.6 2.58 2.65 2.5 2.1 1.95

62
CONCLUSIONS

63
CONCLUSIONS

1. SCBA concrete performed better when compared to ordinary concrete up to

10% replacement of sugar cane bagasse ash.

2. Increase of strength is mainly to presence of high amount of Silica in

sugarcane bagasse ash.

3. Compressive strength is decreased for concrete cured in 5% HCL solution when

compared to the concrete cured in normal water.

4. Compressive strength is increased for 7,14 and 28 days when cured in normal

water, but compressive strength is reduced very low acid attack after cured of

7,14 & 28 days in HCL solutions.

5. It is observed that effect on concrete decreases when exposed to HCL solution.

[Link] of the waste material Sugar Cane Bagasse ash can be advantageously

used as a replacement of cement in the preparation of concrete.

64
REFERENCES

1. [Link] Sekhar Reddy, [Link] Reddy, “Studies on durability

characteristics Of high performance concrete” International journal of

advanced scientific and technical research, issue 2 volume 6, December

2012 ISS 2249-9954.

2. Dr. P. Srinivasa Rao et al., “Durability studies on steel fibre reinforced

metakaolin blended concrete”.

3. P. Murthi and V. Siva Kumar, “Studies on Acid Resistance of Ternary

Blended concrete”, Asia journal of civil engineering (building and housing)

Vol.9, No.5 (2008).

4. A.K. Al-Tamimi and M. Sonebi, “Assessment of self-Compacting Concrete

immersed In Acidic Solutions”.

5. [Link] Reddy et al., “Effect of Hydrochloric Acid on Blended

cement and silica fume blended cement and their concretes”, International

journal of science and technology volume 1 no. 9, September, 2012

6. Beulah M. Asst Professor, Prahallada M. C. Professor, “Effect of

replacement of cement by metakalion on the properties of high performance

concrete subjected to hydrochloric acid attack”, IJERA ISSN: 2248-9622

vol.2, Issue 6, NOV-DEC 2012, pp.033-038.

65
7. G. Siva Kumar et al., “Preparation of Bio-Cement using SCBH and

its Hydration Behaviour”.

8. H.S Otuoze et al., “Characterization of SCBH and ordinary Portland

cement blends in concrete”.

9. Mr. Lavanya M.R et al., “An Experimental study on the compressive

strength of concrete by partial replacement of cement with SCBA”.

[Link] et al., “Experimental study on bagasse ash in concrete”.

[Link] et al., “Effect of use of bagasse ash on strength of concrete”,

International journal of innovative research in science, Engineering and

technology.(July 2013)

12. Lourdes M.S Souza et al., “Hydration study of SCBA and Calcium

Hydroxide pastes of various initial C/S ratios”.

13. Abdolkarim Abbasi and Amin Zargar,” Using Bagasse Ash in Concrete as

Pozzolana”.

14. Piyanut Muangtong et al., “Effect of Fine Bagasse Ash on Workability and

Compressive Strength of Mortars”.

15. Asma Abd Elhameed Hussein et al., “Compressive Strength

and Microstructure of Sugar Cane Bagasse Ash Concrete”.

16. Kanchana lata Sing and S.M Ali Jawaid,(August 2013) , “Utilization of

sugarcane bagasse ash (SCBA) as pozzolanic material in concrete”.

17.V.S Ramachandran et al., “Concrete Admixture Hand Book”.

66
 18. R. Paul Lohlia and Ramesh C. Joshi, “Concrete Admixture Hand Book”.

LIST OF CODES:

o IS: 12269-1987

o IS 383-1970

o IS:2386-1963

o IS:456-2000

o IS: 10262-2009

o IS 516-1959

67

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