A

MAJOR PROJECT REPORT

ON
PREPARATION OF BENDABLE CONCRETE BY USING FIBERS

Submitted in the partial fulfillment of the academic

requirements for the award of degree of
BACHELOR OF TECHNOLOGY

In
DEPARTMENT OF CIVIL ENGINEERING (2019-2020)
By

M SUMAN (16VD1A0150)
KN BHANU (16VD1A0109)
R SHIVA KUMAR (16VD1A0141)
B SAI KUMAR (17VD5A0103)

Under the esteemed guidance of

Dr.N. DARGA KUMAR (Assistant Professor & Head of the department)
Ms. K. SRILATHA (Assistant Professor (c))
Department of Civil Engineering

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

COLLEGE OF ENGINEERING MANTHANI
Pannur (V), Ramagiri (Mdl), Peddapalli-505212,Telangana

i
 DECLARATION

We hereby declare that the work which is being presented in the project report entitled
“PREPARATION OF BENDABLE CONCRETE BY USING FIBERS” submitted in
partial fulfillment for the award of the Degree of BACHELOR OF TECHNOLOGY in
CIVIL ENGINEERING, JNTUH college of Engineering Manthani is an authentic record
of our own work carried out under the guidance of Ms .K SRILATHA (Assistant Professor
(c)), Department of Civil Engineering, JNTUH College of Engineering Manthani,.
This is a record of bonafide work carried out by us and the results embodied in this
project report have not been reproduced or copied from any source. The results embodied in
this project have not been submitted to any other University or Institute for the award of any
degree or diploma.

M SUMAN (16VD1A0150)
KN BHANU (16VD1A0109)
R SHIVA KUMAR (16VD1A0141)
B SAI KUMAR (17VD5A0103)

ii
 CERTIFICATE
This is to certify that the project report entitled “PREPARATION OF BENDABLE
CONCRETE BY USING FIBERS” being submitted by M SUMAN (16VD1A0150), K.N,
BHANU (16VD1A0109), R SHIVA KUMAR (16VD1A0141),B SAI KUMAR
(17VD5A0103) in the partial fulfillment of the requirements for the award of the Degree of
BACHELOR OF TECHNOLOGY in CIVIL ENGINEERING to the JAWAHARLAL
NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD COLLEGE OF
ENGINEERING MANTHANI is a record of bonafide work carried out by them under my
guidance and supervision.
The results of investigation enclosed in this report have been verified and found
satisfactory. The results embodied in this project report have not been submitted to any other
University or Institute for the award of any degree or diploma.

INTERNAL GUIDE HEAD OF THE DEPARTMENT

(Civil engineering)

EXTERNAL EXAMINER PRINCIPAL

Date:

iii
 ACKNOWLEDGEMENT
We express our sincere gratitude to Dr. R. MARKANDEYA, Principal, JNTUH
College of Engineering Manthani for encouraging and giving permission to accomplish our
project successfully.
We express our sincere gratitude to Dr. B. VISHNU VARDHAN, Vice-Principal,
JNTUH College of Engineering Manthani for his encouragement in our project.
We express our sincere gratitude to Dr. [Link] KUMAR, Assistant Professor &
HOD, Civil Engineering, JNTUH College of Engineering Manthani for his excellent
guidance, advice and encouragement in taking up this project.
We express our profound gratitude to our project guide Ms.K Srilatha, (Assistant
Professor(c)) for his constant help, personal supervision, expert guidance and consistent
encouragement throughout this project which enabled us to complete our project successfully
in time.
We also take this opportunity to thank other faculty members of Civil Department for
their kind co-operation.
Finally yet importantly we would like to thank our parents for reposing so much faith
and care in us, giving us the financial and mental support to strive through and complete the
thesis.
We also convey our thanks to one and all those who have extended their helping
hands directly and indirectly in completion of our project.

M SUMAN (16VD1A0150)
KN BHANU (16VD1A0109)
R SHIVA KUMAR (16VD1A0141)
B SAI KUMAR (17VD5A0103)

iv
 ABSTRACT
Bendable concrete also known as engineered cementitious composites abbreviated as
ECC is class of ultra-ductile fibre reinforced cementitious composites, characterized by high
ductility and tight crack width control. This material is capable to exhibit considerably
enhanced flexibility. An ECC has a strain capacity of more than 3% and thus acts more like a
ductile metal rather than like a brittle glass. Reducing the brittle nature of concrete has opened
a new world of possibilities to enhance the safety, durability and sustainability of the next
generation of civil infrastructure. Tiny fibres partly account for its performance, and also the
materials are designed for maximum flexibility. Because of its long life, ECC is expected to
cost less in the long run.

v
 CONTENTS
Name of topic Page no.

Title page i

Declaration ii

Certificate iii

Acknowledgement iv

Abstract v

Chapter- 1: Introduction 01-06

1.1 General 01

1.2 Problem statement 02

1.3 Scope and background 03

1.4 Objectives 04

1.5 Expected outcomes 04

1.6 Advantages 04

1.7 Special features of bendable concrete 04

1.8 Disadvantages of bendable concrete 05

1.9 Methodology 06

Chapter- 2: Literature Review 07-10

Chapter- 3: Materials and properties 11-19

3.1 Introduction 11

3.2 Materials 11

3.2.1 Cement 11

3.2.2 Fine aggregate 12

3.2.3 Sieve analysis 13

vi
 3.2.4 Superplasticizer 15

3.2.5 Fly ash 15

3.2.6 Polypropylene fibres 16

3.2.7 Water 18

3.3 Self- healing property of bendable concrete 18

3.4 Comparison b/w conventional and flexible concrete 19

Chapter- 4: Mix design 20-25

4.1 Introduction 20

4.1.1 Objectives of mix design 20

4.2 Mix design of flexible concrete 20

4.2.1 Design stipulations 20

4.2.2 Test data of materials 21

4.2.3 Procedure for concrete mix design 21

Chapter- 5: Experimental work 26-35

5.1 Introduction 26

5.1.1 Requirements of good concrete mix 26

5.2 Preparation of specimens 26

5.3 Testing of the specimen 30

5.3.1 Compressive strength test 30

5.3.2 Tensile strength test 31

5.3.3 Workability test 32

5.4 Cost analysis 35

5.4.1 Conventional concrete 35

5.4.2 Flexible concrete 35

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Chapter- 6: Results 36-42

6.1 Compressive strength of concrete 36

6.2 Tensile strength of concrete 39

6.3 Slump cone 42

Conclusion 43

Future scope 44

References 45

viii
 LIST OF FIGURES

Name of table Page no.

Figure 1.1 Flexible concrete 02

Figure 1.2 Phases of experimental work 06

Figure 3.1 Cement 11

Figure 3.2 Sand 13

Figure 3.3 Polypropylene fibres 17

Figure 5.1 Weighing balance 27

Figure 5.2 Cube mould of size 150mm 28

Figure 5.3 Prepared moulds 29

Figure 5.4 De moulding of cubes 29

Figure 5.5 Curing of concrete 30

Figure 5.6 Testing of cube 31

Figure 5.7 Testing of specimen 32

Figure 5.8 Slump cone apparatus 33

Figure 6.1 Compressive strength for 7 days 36

Figure 6.2 Compressive strength for 14 days 37

Figure 6.3 Compressive strength for 28 days 38

Figure 6.4 Split tensile strength of concrete for 7 days 39

Figure 6.5 Split tensile strength of concrete for 14 days 40

Figure 6.6 Split tensile strength of concrete for 28 days 41

ix
 LIST OF TABLES
Name of table Page no.
Table 3.1 Properties of cement 12

Table 3.2 Properties of sand 13

Table 3.3 Sieve analysis of fine aggregate 14

Table 3.4 Properties of fly ash 16

Table 3.5 Properties of polypropylene fibres 17

Table 3.6 Difference b/w conventional and flexible concrete 19

Table 4.1 Formulation of trials 20

Table 6.1 Results of compressive strength of concrete for 7 days. 36

Table 6.2 Results of compressive strength of concrete for 14 days 37

Table 6.3 Results of compressive strength of concrete for 28 days 38

Table 6.4 Results of tensile strength of concrete for 7 days 39

Table 6.5 Results of tensile strength of concrete for 14 days 40

Table 6.6 Results of tensile strength of concrete for 28 days 41

Table 6.7 Slump values 42

x
 LIST OF INDICATIONS AND ABBREVIATIONS
ECC: Engineered cementitious composite

W/C: water to cement ratio

Mpa: Mega Pascal

Gpa: Giga Pascal

M25: Concrete grade with compressive strength 25 N/mm2 at the end of 28 days of curing

PSC: Portland slag cement

C/S:. Cement to sand ratio

P: Breaking load

OPC: Ordinary Portland cement

xi
 CHAPTER 1
INTRODUCTION
1.1 GENERAL
Concrete is a mixture of cement, sand and coarse aggregate and that sets after mixing
with water in proportion at certain chemical reaction. In olden days concretes were lime-
based concretes in which binding material was lime. After some development Portland
cement concrete, hydraulic cement were used. Concrete is much strong in compressive
strength, but much lower in tensile strength. Concrete has always been a brittle material, and
cracks easily when subjected to tensile loading. To improve tensile strength it is reinforced
with steel that are strong in tension. The elasticity of conventional concrete is generally
constant at low stress levels but as the stress level increases it starts decreasing as micro
cracking develop. The structures made from conventional concrete develops crack at, due to
shrinkage, tensile stress and creep. Conventional concrete is very rigid and has much lower in
strain about 0.1% that makes concrete brittle and hard. Recently, researchers have turned
such conventional concrete into a new type of concrete that is more ductile than ordinary
concrete. When ordinary concrete is subjected to tensile load, it tends to crack. For this
reason, researchers have long been interested in making concrete more ductile, that is, more
likely to bend than to break under load. Engineered Cementitious Composite (ECC) has
proved to be 50 times more flexible and 40 times lighter than conventional concrete
Additionally, the excellent energy absorbing properties of ECC makes it especially suitable
for critical elements in seismic zones. Researchers at the Advanced Civil Engineering
Material Research Laboratory, in Ann Arbor, Michigan, have spent the past several years
developing what they call an engineered cementitious composite, in essence a highly ductile
type of fiber-reinforced concrete.

Conventional concretes are almost unbendable and have a strain capacity of only
0.1% making them highly brittle and rigid. This lack of bendability is a major cause of failure
under strain and has been a pushing factor in the development of an elegant material namely,
bendable concrete also known as Engineered Cementitious Composites (ECC.) This material
is capable to exhibit considerably enhanced flexibility. A bendable concrete is reinforced
with micromechanically designed polymer fibers.

1
 Fig 1.1 flexible concrete

ECC is made from the same basic ingredients as conventional concrete but with the addition
of High-Range Water Reducing (HRWR) agent as it is required to impart good workability.
However, coarse aggregates are not used in ECCs (hence it is a mortar rather than concrete).
The powder content of ECC is relatively high. Cementitious materials, such as fly ash, silica
fume, blast furnace slag, etc., may be used in addition to cement for increasing the paste
content. Typically, ECC uses 2% by volume of short, discontinuous fibers. ECC incorporates
super fine silica sand and tiny Polyvinyl Alcohol- fibers covered with a very thin (nanometer
thick), slick coating. This surface coating allows the fiber to begin slipping when they are
over loaded so they are not fracturing.

ECC prevents the fiber from rupturing which would lead to large cracking. Thus an
ECC deforms much more than a normal concrete but without fracturing. Fig. 1.1 shows the
behaviour of ECC under flexural loading and it can be seen that the beam can deform well
without direct [Link] different ingredients of ECC work together to share the applied
load. ECC has proved to be 50 times more flexible than traditional concrete, and 40 times
lighter, which could even influence design choices in [Link], the excellent
energy absorbing properties of ECC make it especially suitable for critical elements in
seismic zones.

1.2 PROBLEM STATEMENT

Bendable concrete can bring a revolution because of its some special quality such
flexibility, self-healing , lighter weight, etc. In some countries such as Japan ,Korea, U.S.A,
etc the flexible concrete is used in many structures. But in India, it is still an composite and
requires research for it use.
Concrete is widely used in today’s construction industry. It can take the compressive
load very effectively. But the main problem with the traditional concrete is that it can take

2
stresses. It fails under the tensile load. The flexible concrete seems to be a good solution for
this problem, if it can give the desired flexural strength.
1.3 SCOPE AND BACKGROUND
Engineered cementitious composites developed in the last decade, will contribute to
safer, more durable, and sustainable concrete infra-structure that is cost-effective. This
concrete has thestrain-hardening property but can be processed with conventional equipment.
This concrete has strain capacity of about 3 to 5% as compared to 0.01% of normal
(conventional) concrete. ECC is a unique class of high-performance fiber-reinforced
cementitious composites featuring high tensile ductility and durability. Flexural strength to
the concrete is induced by the fibers admitted to the concrete. The concrete is produced with
2% of optimal volume of different [Link] flexes without fracturing due to the interaction
between fibers, sand and cement working in a matrix that binds everything together within
the material. In addition to reinforcing, the concrete with fibers acts as ligaments to bond it
more tightly. Due to this instead of fracturing, the material undergoes a process called micro-
cracking, wherein the energy of the tensile strain is diffused into a number of tiny cracks
producing cracks of extremely small size, averaging less than 60 µm in width, roughly half
the width of a human hair (Kalepalli,2006). Initially self-healing concrete costs roughly three
times as much as conventional concrete. But its lower lifecycle cost is ascribed to lower
repair frequency and lesser consumption of materials due to its higher ductility and durability
which leads to savings in cost. Further this technology is being advanced by using Iron Ore
Tailings (IOTs) to develop greener engineered cementitious composites (ECCs). Due to the
high cement usage in ECC limits the material greenness and increases the material cost
compared with normal concrete.

Since ECC are more flexible than traditional concrete, it acts more like metal than
glass. Traditional concrete is considered to be a ceramic, brittle and rigid. It can suffer
catastrophic failure when strained in an earthquake or by routine overuse. It is studded with
specially-coated reinforcing fiber that hold it together. ECC remains intact and safe to use at
tensile strains up to 5%. Traditional concrete fractures and can’t carry a load at 0.01 % tensile
strain.
In recent times, builders reinforce concrete structures with steel bars in order to keep
cracks as small as possible. But they are not small enough to heal. So, water and deicing salts
can penetrate till steel, causing corrosion that further weakens the structure. Li’s self-healing
3
concrete needs no steel reinforcement to keep crack width tight, thereby eliminating
corrosion.
1.4 OBJECTIVES
 Detailed study of properties of Engineered Cementitious Composites (ECC) in terms
of compressive strength and flexural strength.
 Preparation of cubes of different ratios and slabs of different depths with varying
percentages of fibers.
 To study the effect on flexural strength for varying depths of ECC by keeping
water/cement ratio constant.
 To compare the cost of ECC with the conventional concrete.
1.5 EXPECTED OUTCOMES
Development of a special type of concrete i.e. ECC also known as flexible concrete
which has very high flexural strength as compared to conventional concrete allowing the
concrete to bend without cracking under heavy loads.

1.6 ADVANTAGES OF BENDABLE CONCRETE

Fibers are not as efficient in withstanding tensile stresses as compared to conventional
steel reinforcement, but fibers are more closely spaced than steel which makes fibers better in
controlling cracks and shrinkage. The following advantages of ECC are summarized,

 Increased crack resistance , more energy absorption capacity, increased toughness and
long term ductility
 Increased impact resistance and shear strength of concrete
 Fiber provides multidirectional reinforcements.
 Ultimate load carrying capacity in flexure is greatly enhanced.
 The weight of flexible concrete is approx. reduced by 20-40%.
 The use of steel reinforcement is reduced.
 Ultimate load carrying capacity in flexure is greatly enhanced.
 The weight of flexible concrete is approx. reduced by 20-40%.

1.7 SPECIAL FEATURES OF BENDABLE CONCRETE

 It has a self- healing property as the cement particles make reaction with the rain
water and makes some complex product that expands and fill the micro cracks that
4
 are developed in the flexible concrete.
 The flexible concrete is proved to be lighter and also proved to be 500 times more
flexible than normal concrete.
 Its ultimate tensile strain capacity is 3 to 5%
 The strain capacity in flexible concrete is 300 times more than the conventional
concrete. Due to this the concrete is act like a flexible material such as metal.
1.8 DISADVANTAGES OF BENDABLE CONCRETE
 It has a high initial cost as compared to conventional concrete.
 It requires skilled labors for its construction
 It needs some special type of materials which can be difficult to find in some areas.
 Its quality depends upon the material used and the condition under which it is made.

5
1.9 METHODOLOGY

Collection of materials (coarse aggregate,fine aggregate(sand),

polypropylene fibers,cement).

Study of properties of materials.

Mix design for (M25).

Preparation of test specimen.

Testing for compressive strength and split tensile strength.

Cost analysis

Results.

conclusion

Fig 1.2 Phases of experimental work

6
 CHAPTER 2
LITERATURE REVIEW
Li [2007] says that final failure of the specimen occurs when one of the multiple cracks forms
a fracture plane. Beyond this peak load, ECC is no different than normal Fiber Reinforced
Concrete, showing a tension-softening response. The high tensile ductility is of great value in
enhancing the structural ultimate limit state (ULS) in terms of structural load and deformation
capacity as well as energy absorption. In this manner, ECC can offer structural safety
improvements. The formation of multiple micro cracking is necessary to achieve high
composite tensile ductility. Between first cracking strain (about 0.01%) and 1% strain, the
micro-crack opening increases from zero to about 60 µm. Further loading beyond 1% causes
more multiple cracks to form, but with no additional crack opening beyond the steady state
value of 60 µm. Governed by the mechanics of the fiber-matrix interaction within ECC, this
unique characteristics critically important for durability of both material and structure. Unlike
concrete or FRC, the steady state crack width is an intrinsic material property, independent of
loading (tension, bending or shear), structure size and geometry, and steel reinforcement type
and amount. This observation has important implications in service life, maximum member
size, economics, and architectural aesthetics. In short, where steel reinforcement is used to
control crack within concrete, such steel reinforcement can be completely eliminated in ECC.
With even in the presence of large imposed structural deformations, ECC can offer structural
durability improvements in addition to water tightness and other serviceability enhancements.
The compressive properties of ECC are not significantly different from normal to high
strength concrete. Compressive strength of ECC ranges from 30MPa to 90MPa. With an
elastic modulus (around 20-25 GPa) typically lower than concrete due to the absence of
coarse [Link] compressive strain capacity of ECC is slightly higher around 0.45-
0.65%.The post-peak behavior of ECC under compression tends to descend more gently than
high strength concrete, accompanied by a gradual bulging of the specimen rather than
explosive crushing [Link] has significant improvements in fatigue response over normal
concrete and FRC.
Şahmaran et al.[2008] investigated the cracking behavior and residual flexural load
capacities of reinforced ECC specimens, which have equal compressive strength to the ECC.
During accelerated corrosion test at constant applied voltage, corrosion-induced crack width

7
of the mortar specimens were found to increase with time as corrosion activity progressed.
Larger crack widths up to 2.00 mm were observed at higher levels of corrosion. Moreover,
corrosion of reinforced mortar beam specimens resulted in a marked reduction in stiffness
and flexural load capacity. After 25 hours accelerated corrosion exposure, the flexural load
reduced to about 34 % of the flexural capacity of the control mortar beam. On the other hand,
crack widths(~0.1mm)of ECC remained nearly constant with time as corrosion activity
progresses, while the number of cracks on the surface of the ECC specimens increased. The
results of this study also showed that ECC has significant anti-spalling ability compared with
conventional mortar. Şahmaran & Li[2009] have stated that in terms of transport properties,
micro-cracks induced by mechanical pre-loading increase the permeability, the chloride
transport. However, the risk of water transport by permeability and capillary suction, and
chloride transport by diffusion in ECC, cracked or uncracked is found to be comparable or
lower with that in normal sound concrete without any cracks. Apart from the slight reductions
in ultimate tensile strain and strength capacities and higher residual crack width, the results
found in the studies summarized in this paper largely confirm the durability performance of
ECC material under accelerated aging (exposure to freeze-thaw cycles with and without de-
icing salts, continuous sodium hydroxide at 38°C and sodium chloride solutions at room
temperature (marine environment and hot and humid environment) even in cases where the
material experiences mechanical loading that deforms it into the strain-hardening stage prior
to exposure. Healing of micro- cracks induced by the preload is evident from the micro-
structural studies and recovery of elastic stiffness of the exposed pre-cracked specimens on
reloading. Li [2009] after research has stated that as a structural material, ECC maintains all
the advantages of concrete, but overcomes its familiar brittleness in tension. Experimental
studies confirm that ECC is highly damage tolerant under extreme loading, including reverse
cyclic loading and low velocity impact. Between first cracking strain (about 0.01%) and 1%
strain, the micro-crack opening increases from zero to about 60μ[Link] loading beyond
1%causes more multiple cracks to form, but with no additional crack opening beyond the
steady state value of 60μm. This unique characteristics critically important for durability of
both material and structure. The elastic modulus (around 20-25GPa) of ECC is typically
lower than that of concrete due to the absence of coarse aggregates. The compressive strain
capacity of ECC is slightly higher, around 0.45-0.65%. Apart from resisting earthquake
loads, ECC will likely perform well under hurricane loading, although more studies need to
be conducted to confirm this. The moderate fiber content (2% or less by volume) makes ECC
8
easily adaptable to construction project execution in the field or to precast plant structural
element production. Indeed, ECC has demonstrated to possess flexibility in processing routes,
including on-site self-consolidating casting, and spraying, as well as off-site recasting and
extrusion.
Zhou & Pan[2014] stated that Due to the lack of aggregate, the modulus of ECC is
lower than concrete with similar strength. Based on the test results, a regression equation is
proposed to obtain the elastic modulus of ECC from its compressive strengths. The strain at
peak load is between 0.004 and 0.005 for the tested ECC compositions, and there is little
correlation between the peak strain and the compressive strength. Moreover, addition of PVA
fiber has little effect on the strain at peak stress. For ECC material, the Poisson’s ratio
increases slightly with the compressive strength when the strength is lower than 50 MPa.
However, when the strength exceeds 50 MPa, the Poisson’s ratio stays almost constant, at a
value higher than that for concrete of similar strength. The toughness index of ECC decreases
with compressive strength.
Gandhiya [2015]said that Compressive strength decreases with the increase in the
cementitious material i.e. fly ash, silica fume, LP etc. Incorporation SL into matrix can
effectively increase compressive strength at all ages, especially at early age. The water to
cementitious material (w/c) ratio 0.27 gives the best result. The ductility in direct shear
depends on the fiber orientation and is significantly improved when the fibers are
perpendicular to the shearplane.
Ian et al (2016) have explained that unconfined compressive strength on day 7
increases by 42% and on day 28 increases by 13% and on day 90 increases by 26%. Thus, the
compressive strength of PECR is superior to that of CCR. Apparent self-healing properties
are hardly seen in the CCR, but the PECR has excellent performance in self-healing. Its
compressive strength increases by 57.3% after self-healing.
Zhang [Link] (2017) have said that mechanical properties of PVA steel hybrid fibre
reinforced ECC with a high strength cement matrix were experimentally investigated. Effects
of additional steel fibres, apart from a constant content of PVA fiber in the composite,
compressive, bending, and tensile behavior were studied. The cracking and tensile strength of
the composites obviously increases with the addition of steel fiber. The additional steel fiber
can also increase the tensile strain capacity of the composites. However, a moderate amount
of steel fibers is needed to obtain a positive response on the tensile strain of the composites.
The individual crack width in the multiple cracking period is significantly decreased with the
9
steel fiber addition. A reduction in crack width of more than 50% with the achieved tensile
strength is observed with the addition of steel fiber.
[Link] [Link] studied that fracture controlled failure is exhibited by the ECC under
flexural loading and a bend is obtained because of crack controlling nature. In the bendable
concrete for the mixes having 30% replacement of cement with flyash the best mix which is
obtained at cement/ sand ratio 1:0.5 and having 3% volume of fibers

10
 CHAPTER 3
MATERIALS AND PROPERTIES
3.1 INTRODUCTION
Engineered Cementitious composite is a composition of cement, sand, fly ash, water,
small amount of admixtures and an optimal amount of fibers. In the mix, coarse aggregates
are deliberately not used because property of ECC Concrete is formation of micro cracks with
large deflection. Coarse aggregates increase crack width, which is contradictory to the
property of ECC Concrete.

3.2 MATERIALS
 Cement
 Fly ash
 Fine aggregate
 Poly propylene fibers
 Super plasticizer
3.2.1 CEMENT
Cement is a bonding material having adhesive and cohesive properties. Cement used
normally is Ordinary Portland cement. Numerous organic compounds which are used for
adhering or fastening materials are called cements. But, these are classified as adhesives, and
the term cement alone means a construction material. Blast furnace slag may also be used in
some cements and the cement is called Portland slag cement (PSC). The color of the cement
is due mainly to iron oxide. In the absence of impurities, the color would be white. The
cement is available in the market in three grades namely OPC 33, OPC43, OPC53. The grade
represents the maximum strength of the particular cement after 28 days. Ordinary Portland
cement (OPC) – 53 grade (Ultra tech Cement) is used in this project..

The chief chemical components of ordinary Portland cement are:

 Calcium
 Silica
 Alumina
 Iron

11
 Fig3.1 Cement

Physical Properties of cement are:

Table3.1 Properties of Cement

Properties Value

Specific gravity 3.14

Initial setting time ( min) 30

Final setting time (min) 330

3.2.2 FINE AGGREGATE

Fine aggregate / natural sand is an accumulation of grains of mineral matter derived
from the disintegration of rocks. It is distinguished from gravel only by the size of the grains
or particles. But it is distinct from clays which contain organic materials. Sands that have
been sorted out and separated from the organic material by the action of currents of water or
by winds across arid lands are generally quite uniform in size of grains. Usually commercial
sand is obtained from river beds or from sand dunes originally formed by the action of winds.
The most commercially used are silica sands, often above 98% pure. Beach sands usually
have smooth, spherical to ovoid particles from the abrasive action of waves and tides and are
free of organic matter. The white beach sands are largely silica but may also be of zircon,
monazite, garnet, and other minerals. Sand is used for making mortar and concrete and for
also used for polishing and sandblasting. Sands containing a little clay are used for making
molds in foundries. Clear sands are employed for filtering water. The weight varies from
1,538 to 1,842 kg/m3, depending on the composition and size of grain. The fine aggregate

12
passing through 4.75 mm sieve with a specific gravity of 2.68 is normally used. The grading
zone of fine aggregate will be zone III as per Indian Standard specifications.

Fig 3.2 River sand

Table 3.2 Properties of sand

Properties Value
Specific gravity 2.64
Fineness modulus 3.03
Density 1.63gm/cc
Surface texture Smooth
Shape Rounded

3.2.3 SIEVE ANALYSIS

Purpose:
This test is performed to determine the percentage of different grain sizes, fineness
modulus of the aggregates for the sample.
Apparatus
Indian standard test sieves, weighing balance ,sieve shaker etc
Sieves to be used are:
 For fine aggregate- 4.75mm, 2.36mm, 1.18mm, 600 microns, 300 microns and 150
microns.
 For coarse aggregate- 80mm ,60mm, 40mm,25mm,20mm 12.5mm, 10mm, 4.75mm
Fineness modulus
Fineness modulus is an empirical factor obtained by adding the cumulative
percentages of aggregate retained on each of the standard sieves ranging from 80 mm to 150
micron and dividing this sum by 100. Fineness modulus is generally used to get an idea of
how coarse or fine the aggregate is. More fineness modulus value indicates that the aggregate

13
is coarser and small value of fineness modulus indicates that the aggregate is finer. Generally
sand having fineness modulus more than 3.2 is not used for making good concrete
Test procedure
1. Prepare a test sample of known weight and put it in oven dry it to constant mass.
2. Arrange sieves in appropriate order ( 10mm, 4.75mm,2.36mm,600micron,300 micron
and 150 micron for fine aggregate and (80mm,63mm, 50mm, 40mm, 31.5mm,
25mm20mm,10mm, 6.35mm) for coarse aggregate.
3. Place the test sample of known weight on the top sieve.
4. Agitate( shake) the set of sieve by hand or by mechanical shaker for a sufficient
period (10min). Prevent an overload of material on an individual sieve by splitting the
sample into two or more portions, sieving each portion individually and then combine
the masses of the several portions retained on specific sieve before calculating the
percentage of sample on the sieve.
5. Open the set of sieves carefully so that no loosing of materials is expected.
6. Record the weight of aggregate retained on each sieve.
7. Calculate the cumulative weight of aggregate retained on each sieve.
8. Make sure that the summation of the residue weighs equal to the original sample
weight with a difference not more than 1% of the original weight.
9. Tabulate the data
Data of fine aggregate
Dry weight of fine aggregate = 2000gm
Table 3.3 Sieve analysis of fine aggregate

Weight Cumulative Cumulative

Cumulative
Sieve Size retained Weight retained % weight
% passing
(gm) (gm) retained
4.75mm 0.075 0.075 3.75 96.25
2.36mm 0.145 0.220 11 89
1.18mm 0.605 0.825 41.25 58.75
600 micron 0.290 1.115 55.75 44.25
300 micron 0.735 1.850 92.5 7.5
150 micron 0.135 1.985 99.25 0.75
Pan 0.015 2.000 100 0

14
Fineness modulus = cumulative percentage retained upto 150 micron/100
= 303 / 100
= 3.03
And the grade of sand is zone II

3.2.4 SUPERPLASTICIZER
Super plasticizers are additives to fresh concrete which help in dispersing the cement
uniformly in the mix. This is achieved by their deflocculating action on cement agglomerates
by which water entrapped in the groups of cement grains is released and it is available for
workability. Typically super plasticizer increase slump from say 5 cm to about 18-20 cm
without addition of water. When used to achieve reduction in mixing water they can reduce
water up to 15-20% and hence decrease W/C ratio by same amount. This results in increase
in strength and other properties like density, water tightness. Where thin sections are to be
cast super plasticizer can increase workability to pumpable level and almost no compaction is
required. This helps in avoiding honeycombing. The permeability of concrete is a guide to its
durability. Gross porosity is usually due to continuous passage in the concrete due to poor
compaction or cracks which can be minimized by the use of super plasticizer, the
incorporation of which provides increased workability maintaining low w/c ratio. It is
reported that coefficient of permeability of cement paste reduces considerably with the
reduction in w/c ratio. Thus super plasticizer can be used effectively to improve the
properties of concrete and avoid defect. Melamine based Super plasticizer are used to assess
their effectiveness in improving durability. Melamine based super plasticizer are reported to
be the best and hence chosen for the research work. Super plasticizers are synthetic water
soluble organic substances that reduce the amount of water required to achieve certain
stability of concrete, reduce water-cement ratio, reduce cement content and increase slump.
Super plasticizers are high range water reducers. The super plasticizer used is CAC hyper
fluid R200.

3.2.5 FLYASH
Fly ash used is pozzocrete dirk 60. And specifications provided by suppliers are given
in Table 1. In RCC construction, use of fly ash has been successful in reducing heat
generation without loss of strength, increasing ultimate strength beyond 180 days, and
providing additional fines for compaction. Replacement levels of primary class fly ash have
15
ranged from 30-75% by solid volume of cementitious material. In proportioning mixes, for
minimum paste volumes, one of principal function of a fly ash is to occupy void space which
would otherwise be occupied by cement or water. Occupation of void space with water would
obviously result in reduction in concrete strength. The fact is that even a small amount of free
lime liberated from cement is sufficient to react with large volume of fly ash. The huge
amount of fly ash is produced in the thermal power stations. Class F fly ash is utilized so the
acquisition cost may be reduced.

Table 3.4 Properties of flyash

Parameters Properties

Bulk density (gm/cc) 0.91-1.3

specific gravity 1.6-2.6

Plasticity lower or non- plastic

grain size fine sand

clay (%) negligible

Texture sandy silt to silty loam

Porosity (%) 30- 65

surface area (m2/kg) 500-5000

3.2.6 POLYPROPYLENE FIBERS

Polypropylene is a hundred percent synthetic fiber which is transformed from 85%
propylene. The monomer of polypropylene is propylene. Polypropylene is manufactured from
propylene gas in presence of a catalyst such as titanium chloride. Polypropylene is a by-
product of petroleum. The fiber is thermoplastic, resilient, light weight and resistant to
mildew and different chemicals. These fibers provide flexibility, tensile strength to the
concrete. These fibers reduce the plastic shrinkage crack area due to their flexibility. The
extent of crack reduction is proportional to the fiber content in the concrete. The elongation
due to these fibers in concrete is about 6 to 10% when compared to conventional concrete.

16
Physical and chemical Properties
 Tough, flexible and has good resistance to fatigue
 The fiber is usually transparent
 Colorless, odorless, tasteless and non toxic
 Resistance to temperatures above 1000o C
 Resistance to O2, steam, grease and other gases.
Advantages of using polypropylene fibers
 Can be easily and evenly dispersed when mixed with mortar or cement
 Convenient to use
 Economical , only need small quantity to produce flexibility to concrete
 It has good heat insulating properties and is highly resistant to acids, alkalis and
organic solvents.
Specifications of the polypropylene fibers used in this project are:
Table 3.5 Properties of polypropylene fibers
Parameters Specification
Size 6mm
Density 0.91 gm/cc
Elongation (%) 40 to 100
Color White
Moisture absorption 0 to 0.05
Abrasion resistance good
Softening point 140o C
Melting point 165o C
Chemical resistance excellent

Fig 3.3 Polypropylene fibers

17
3.2.7 WATER
Water fit for drinking is generally considered fit for making concrete. Water should be
free from acids, oils, alkalis, vegetables or other organic Impurities. Soft waters also produce
weaker concrete. Water has two functions in a concrete mix. Firstly, it reacts chemically with
the cement to form a cement paste in which the inert aggregates are held in suspension until
the cement paste has hardened. Secondly, it serves as a vehicle or lubricant in the mixture of
fine aggregates and cement.
3.3 SELF HEALING PROPERTY OF BENDABLE CONCRETE
For the most part, the self healing process simply takes the advantage of materials
already present in conventional concrete, explains. Even in ordinary concrete a significant
percentage of the cement grains remain unused and dormant because they are never hydrated.
Cracks in the concrete expose these residual cement grains to the air and water in the
surrounding environment. Under the right conditions, the un hydrated grains react chemically
with water and the carbon dioxide in the air to form strong compounds known as calcium
carbonates. The fractures in conventional concrete are generally so wide that even when
calcium carbonates do form they provide virtually no benefit. However, when the cracks are
small enough no more than 50 µm these compounds can accumulate in such a way as to fill
the cracks, thus repairing the concrete and leaving behind nothing but a scar. Most important
of all, the self-healing concrete recovers its essential properties, including its ductility, its
stiffness, and its ability to resist the intrusion of such corrosive agents as water and road salt,
In general, the self-healing concrete consists of the same Portland cement, water, sand, and
chemical admixtures that are already present in conventional concrete. The difference is that
the chemical, mechanical, and geometric properties and proportions of these ingredients are
fine-tuned to promote the self-healing process, Li says.

18
3.4 COMPARISON B/W CONVENTIONAL AND BENDABLE
CONCRETE
Table 3.6 Difference between conventional and bendable concrete

Parameter Conventional concrete bendable concrete

The normal concrete structure are The flexible concrete

Durability
less durable structures are more durable

As the flexible concrete

The structures made with the
does not break easily by the
original concrete are prone to
Earthquake earthquake motion. So the
earthquake. They generally forms
resistance structure made with the
cracks or may collapse during
flexible concrete are more
earthquake
earthquake resistant
The flexible concrete has a
The normal concrete has very low very good self healing as it
Self healing property self- healing property as it has can heal the micro-cracks
very low free cement concrete itself by the reaction of
carbon dioxide and water.
The repair & maintenance
The repair &maintenance cost of
Repair and cost of flexible concrete is
concrete structure is high as it
maintenance less as it does not develop
develops cracks and other defects.
that much cracks
The fiber reinforcement can
provide the require tensile
The steel bar reinforcement is
Reinforcement strength in the concrete so
require for taking tensile load
less or may be steel
reinforcement is require.

It requires more skilled

Labor It requires less skilled labor
labor

19
 CHAPTER 4
MIX DESIGN
4.1 INTRODUCTION
Mix design can be defined as the process of selecting suitable ingredients of concrete
and determining their relative proportions with the objective of producing concrete of certain
minimum strength and durability as economically as possible.
The concrete mix design involves various steps, calculations and laboratory testing to
find right mix proportions. Benefits of concrete mix design is that it provides the right
proportions of materials, thus making the concrete construction economical in achieving
required strength of structural members. As, the quantity of concrete required for large
constructions are huge, economy in quantity of materials such as cement makes the project
construction economical.
4.1.1 OBJECTIVES OF MIX DESIGN
The purpose of concrete mix design is to ensure the most optimum proportions of the
constituent materials to fulfill the requirement of the structure being built. Mix design should
ensure following objectives
 To achieve the designed/desired workability in the plastic stage.
 To achieve the desired minimum strength in the hardened stage.
 To achieve the desired durability in the given environment conditions.
 To produce concrete as economically as possible.
4.2 MIX DESIGN OF FLEXIBLE CONCRETE
From the literature review and case studies, it is observed that the trial ratios
suggested by different researchers vary from each other. It is due to variation in the properties
of materials like fibers, w/c ratio and type of fiber. Some of the trial ratios from the studies
are: 1:1:1 with fibers 1% and 1.2% and 1:0.5 with 3% volume of fibers .From the case studies
we adopted M25 concrete grade with mix ratio1:1(cement: sand) with water cement ratio
0.35 and instead of coarse aggregate fibers are used in varying percentages like1%, 1.2% of
fibers and also to increase workability of concrete required amount of super plasticizer is
used. We performed two trials by varying the percentage of the fiber content i.e.0% 1% and
1.2%.

20
4.2.1 Design Stipulations
1. Concrete grade : M25
2. Minimum cement content : 300 kg/m3
3. Maximum water- cement ratio : 0.5
4. Exposure condition : mild
4.2.2 Test Data of Material
1. Cement used : OPC 43
2. Specific gravity of cement : 3.14
3. Specific gravity of fine aggregate : 2.64
4. Specific gravity of coarse aggregate : 2.76
5. Grade of sand : zone II
Table 4.1 Formulation of trials

Coarse
Batch mix Cement(%) Flyash (%) Fiber (%) Sand(%)
aggregate
1 50 50 0 100 100

2 49 50 1 100 0

3 48.8 50 1.2 100 0

4.2.3 Procedure for concrete mix design

Trial 1:
In this trial concrete grade of M25 was adopted with 0% fibers (conventional concrete)
QUANTITY ESTIMATION OF MATERIALS FOR CUBE:
Volume of concrete for 6 cubes = 015*0.15*0.15*9 = 0.030375m3
Dry volume of concrete = 1.54 times the wet volume
= 1.54*0.03075
=0.046m3
Mix ratio= 1:1:2 (cement : sand : coarse aggregate)
 Calculation of cement content :
Cement content = (1/4)*0.046*1440
=16.56g
 Calculation of sand content

21
 Fine aggregate content= 16.56 kg
 Calculation of coarse aggregate content:
Coarse aggregate content= 33.12kg
 Calculation of water content:
Water- cement ratio= 0.45
Water content= 0.45*16.56kg
= 7.452 liters
QUANTITY ESTIMATION OF CONSTITUENTS FOR CYLINDER:
Volume of concrete for 9 cylinders = ( π/4)×(015)2×0.39 = 0.0477m3
Dry volume of concrete = 1.54 times the wet volume = 1.54*0.0477=0.0735m3
Mix ratio= 1:1: 2 (cement : sand: coarse aggregate )
 Calculation of cement content :
Cement content = (1/4)*0.0735*1440
=26.46kg
 Calculation of sand content:
Fine aggregate content= 26.46kg
 Calculation of coarse aggregate content:
Fly ash content= 52.92kg
 Calculation of water content:
Water- cement ratio= 0.45
Water content= 0.45*26.46kg
= 11liters
Trial 2:
In this trial ,1% fibers are used eliminating coarse aggregate
QUANTITY ESTIMATION OF CONSTITUENTS FOR CUBES:
Volume of concrete for 6 cubes = 015*0.15*0.15*9 = 0.030375m3
Dry volume of concrete = 1.57 times the wet volume
= 1.54*0.030375
=0.046m3
Fibers constitute about 1% of the total volume. Therefore 99% volume constitutes for dry
materials. Dry volume (99% volume) =0.0455m3
Mix ratio= 1:1 (cement : sand )
= 0.5:0.5:1 (cement: flyash: sand)
22
  Cement content = (0.5/2)*0.0455*1440
=16.38kg
 Fly ash content= 16.38kg
 Fine aggregate content= 32.76kg
 Calculation of water content:
Water- cement ratio= 0.35
Water content= 0.35*32.76kg
= 11.46 liters
 Calculation of fiber content:
Fiber content= 1%of volume
Fiber content=(1/100)*0.0460*910= 0.61kg
 Calculation of super plasticizer content:
Super plasticizer content = 6ml/kg of cement
= 6*32.76 =196.56 ml
QUANTITY ESTIMATION OF CONSTITUENTS FOR CYLINDERS:
Volume of concrete for 9 cylinders = ( π/4)×(015)2×0.39 = 0.0477m3
Dry volume of concrete = 1.54 times the wet volume
= 1.54*0.047 =0.073m3
Mix ratio= 1:1 (cement : sand)
50% of cement is replaced with flyash
Mix ratio = 0.5:0.5:1 ( cement: flyash: sand)
 Calculation of cement content :
Cement content = ( 0.5/2)*0.072*1440
=26kg
 Calculation of flyash content:
Flyash content= 26kg
 Calculation of fine aggregate content:
Fine aggregate content= 52 kg
 Calculation of water content:
Water- cement ratio= 0.35
Water content= 0.35*24kg
= 8.4 liters

23
  Calculation of fiber content:
Fiber content= 1%of volume
= (1/100)*0.073*910= 0.95kg
 Calculation of super plasticizer content:
Super plasticizer content = 6ml/kg of cement
= 6*52 =312 ml
Trial 3:
In this trial , 1.2% fibers are used eliminating coarse aggregate
QUANTITY ESTIMATION OF CONSTITUENTS FOR CUBES:
Volume of concrete for 6 cubes = 015*0.15*0.15*9 = 0.030375m3
Dry volume of concrete = 1.57 times the wet volume
= 1.54*0.030375
=0.046m3
Fibers constitute about 1.2% of the total volume. Therefore 98.8% volume constitutes for dry
materials. Dry volume (98.8% volume) =0.045m3
Mix ratio= 1:1 (cement : sand )
= 0.5:0.5:1 (cement: flyash: sand)
 Cement content = ( 0.5/2)*0.045*1440=16.2kg
 Fly ash content= 16.2kg
 Fine aggregate content= 32.4kg
 Calculation of water content:
Water- cement ratio= 0.35
Water content= 0.35*32.76kg
= 11.34 liters
 Calculation of fiber content:
Fiber content= 1.2%of volume
=(1.2/100)*0.0460*910
= 0.72kg
 Calculation of super plasticizer content:
Super plasticizer content = 6ml/kg of cement
= 6*32.4 =194ml
QUANTITY ESTIMATION OF CONSTITUENTS FOR CYLINDERS:
Volume of concrete for 9 cylinders = ( π/4)×(015)2×0.39 = 0.0477m3
24
Dry volume of concrete = 1.54 times the wet volume
= 1.54*0.0477
=0.073m3
Dry volume (98.8% of total volume)= 0.072 m3
Mix ratio= 1:1 (cement : sand)
50% of cement is replaced with flyash
Mix ratio = 0.5:0.5:1 ( cement: flyash: sand)
 Calculation of cement content :
Cement content = ( 0.5/2)*0.072*1440=26kg
 Calculation of flyash content:
Flyash content= 26kg
 Calculation of fine aggregate content:
Fine aggregate content= 52 kg
 Calculation of water content:
Water- cement ratio= 0.35
Water content= 0.35*24kg
= 8.4 liters
 Calculation of fibre content:
Fibre content= 1.2%of volume
= (1.2/100)*0.072*910
= 1.14kg
 Calculation of super plasticizer content:
Super plasticizer content = 6ml/kg of cement
= 6*52 =312ml

25
 CHAPTER 5
EXPERIMENTAL WORK
5.1 INTRODUCTION
Concrete is a mixture of cement , sand , aggregates and water. When these ingredients
are mixed together it forms a fluid mass which can be easily moulded into [Link]
properties of concrete depends upon the proportions and type of the ingredients. Production
of quality concrete requires meticulous care exercised at every stage in the mix. A properly
designed concrete mix is very durable.

5.1.1 Requirements of good concrete mix

 The concrete should be mixed thoroughly to form a homogeneous mix
 Concrete should be compacted properly to prevent it from being porous.
 Sufficient curing of concrete is required for developing full strength
 The water cement ratio should be appropriate considering the strength and workability
criteria
 The concrete mix should be designed properly and should have all the ingredients in
right proportions
5.2 PREPARATION OF SPECIMENS
The following are the steps involved in preparing concrete specimens
 Batching
 Mixing
 Assembling cube moulds
 Placing and compaction
 Demoulding and curing
Equipment
1. Trowels
2. Sample tray;
3. Mould for making test cube;
4. Spanners;
5. Scoop;
6. Steel float or trowel;
26
 7. Compacting bar;

1. BATCHING
The quantities of cement, aggregates, and water for each batch shall be determined by
weight, to an accuracy of 0.1 percent of total weight of the batch by using the weighing
balance and collected into the trays. Batching is the process in which quantity or proportion
of materials like cement, aggregate, water etc., or measured on the basics of either weight or
volume to prepare concrete mix. Proper batching improve the workability of concrete by
reducing the segregation or bleeding in concrete.

Fig 5.1 weighing balance

2. MIXING
Mixing of cement, fine aggregate, fibers and water.

Hand mixing:
The hand mixing of concrete may be done as detailed below:
 Depending upon the quantity of concrete to be mixed, take a tray of suitable size.
 Spread the required quantity of fine aggregates (sand) on the tray and then spread the
required quantity of cement uniformly over the sand layer.
 With the help of shovels, mix the sand and cement in dry state till a mixture of
uniform colour is obtained.
 Now add the amount of polypropylene fibers in the mixture and mix the mixture in
dry state thoroughly.
 On obtaining a uniform coloured mix, make a depression in the centre of the mixed
materials.
 Measure the amount of superplasticizer to be added ,using measuring jar .
 Add 50 % the required quantity of water (based on the water-cement ratio) in the
27
 depression and also add the measured super plasticizer so that water and super
plasticizer gets mixed uniformly and turn the mix towards the middle, with the help of
hands or shovels. The mixture is mixed thoroughly till a uniform colour and
consistency is obtained.
 Add the remaining quantity of water and continue the mixing process till a concrete of
uniform consistency is obtained
3. CUBE MOULDS
For casting cube specimens, standard cast iron metal moulds of size
150mm×150mm×150mm are used. Cubes of 100 mm size are not suitable for concrete
having a nominal maximum aggregate size exceeding 20 mm. Each mould has a base, which
is a separate metal plate, preferably fastened to the mould by clamps or springs. When
assembled, all the internal angles of the mould must be right angles. Before assembling the
moulds, make sure that there is no hardened mortar or dirt on the faces of the flange that
prevent the sections from fitting together closely. After assembling the mould, inside of the
mould should be oiled to prevent the concrete from sticking to it.

Fig 5.2 Cube mould of size 150mm

4. PLACING AND COMPACTION

The mixed concrete is placed in the moulds using a trowel in three layers of equal
depth followed by compaction. Compaction of concrete is a process adopted for expelling the
entrapped air from the concrete. In the process of placing and mixing of concrete, air is likely
to get entrapped in the concrete. If this air is not removed the concrete looses strength
considerably. In this present investigation, in order to achieve full compaction, compacting
bar or tamping rod is used. Each layer of concrete is compacted with 25 strokes with the
rounded end of the rod. The strokes should be distributed in a uniform manner over the whole
surface of concrete. After the top layer has been compacted, excess concrete is removed with
28
trowel and top surface is finished to smooth level and the outside of the mould should be
wiped clean.

Fig 5.3 Prepared moulds

5. DEMOULDING AND CURING
Demoulding of cubes
Test cubes should be demoulded after 24 hours they have been made. When removing
the concrete cube from the mould, take the mould apart completely. Take care not to damage
the cube because, if any cracking is caused, the compressive strength may be reduced.
After demoulding, each cube should be marked with a legible identification on the top
or bottom using a waterproof crayon or ink. The mould must be thoroughly cleaned after
demoulding the cube. Ensure that grease or dirt does not collect between the faces of the
flanges, otherwise the two halves will not fit together properly and there will be leakage
through the joint and an irregularly shaped cube may result.

Fig 5.4 Demoulding of cubes

Curing of cubes
Cubes must be cured before they are tested. Unless required for test at 24 hours, the
cubes should be placed immediately after demoulding in the curing tank or mist room. The
curing temperature of the water in the curing tank should be maintained at 27-30°C. If curing
is in a mist room, the relative humidity should be maintained at no less than 95%. Curing

29
should be continued as long as possible up to the time of testing.
In order to provide adequate circulation of water, adequate space should be provided
between the cubes, and between the cubes and the side of the curing tank. If curing is in a
mist room, there should be sufficient space between cubes to ensure that all surfaces of the
cubes are moist at all times.

Fig 5.5 Curing of concrete.

5.3 TESTING OF THE SPECIMEN:

5.3.1 Compressive Strength Test:

Compressive strength of a concrete is a measure of its ability to resist static load, which
tends to crush it. Most common test on hardened concrete is compressive strength test. It is
because the test is easy to perform. Furthermore, many desirable characteristic of concrete are
qualitatively related to its strength and the importance of the compressive strength of concrete
in structural design. The compressive strength gives a good and clear indication that how the
strength is affected with the increase of fibre volume dosage rate in the test [Link]
test was performed to find the increase and differences of strength according the cement to
sand ratio in concrete.

Apparatus
 Compressive testing machine
 Cube moulds

Test Procedure

The test procedure was in accordance to IS: 516 - 1959. The procedure of the testing was as
follow,

30
  Test was conducted immediately after removal of cubes from curing while they are still
in wet condition.
 Surface water was cleaned, grit and any projecting fins were removed.
 The platens of the testing machine were cleaned to ensure it is free from films of oil
and particles of grit.
 The specimen was placed in the testing machine (between the two platens). The axis of
the specimens was carefully aligned.
 Load was applied without shock and increasing continuously at a rate of 140
kg/sqcm/min.
 The compressive strength of the specimen was obtained from the machine directly.

Fig 5.6 Testing of cube

5.3.2 Tensile Strength Test:

The splitting Tensile Strength indicates an increasing trend of tensile strength when
fibers are added to concrete. Whereas for Bendable Concrete the strength is more when
compared with PCC. we can see the variation of flexural strength with cement/sand ratios.
replacement of fly ash with cement as 30% there is a gradual decrease of splitting tensile
strength from C/S ratio 1:0.5 to 1:0.8, and then maximum strength obtained at 1:0.5 C/S ratio
for mix BC 12 has more splitting tensile strength is obtained as 5.53 MPa. we got an
increasing splitting tensile strength for 40% replacement of fly ash with cement. when the
volume of fibers is 2% there is noted strength obtained.
Procedure of Splitting Tensile Test
 After curing, wipe out water from the surface of specimen
 Using a marker, draw diametrical lines on the two ends of the specimen to verify that
they are on the same axial place.
31
  Measure the dimensions of the specimen.
 Keep the plywood strip on the lower plate and place the specimen.
 Align the specimen so that the lines marked on the ends are vertical and centered over
the bottom plate.
 Place the other plywood strip above the specimen and bring down the upper plate to
touch the plywood strip.
 Apply the load continuously without shock at a rate of approximately 14-21
kg/cm2/minute (Which corresponds to a total load of 9.9 ton/minute to 14.85
ton/minute)
 Write the breaking load (P)

Split Tensile Strength

Tsp = 2P/ pi DL
where
Tsp = split tensile strength
P is the actual failure load
D= diameter of the specimen
L= length of the specimen

Fig 5.7 Testing of specimen

5.3.3 WORKABILITY TEST

Workability is an important property of concrete. In simple terms, it can be defined as
the ease with which the concrete can be mixed, transported, placed and compacted. It can also
be defined as the amount of work required to place concrete and to compact it thoroughly.
Workability of concrete increases with the addition of water but it reduces the strength.
Slump test is the most commonly used method of measuring consistency of concrete.

32
It measures the consistency or moisture of the concrete, which gives an idea of the
workability of the concrete mixture. This test plays a vital role in ensuring immediate
concrete quality of the concrete mixture. This is the simplest test of workability for concrete,
involves low cost and provides immediate results.
OBJECTIVE
To determine the value of slump by using the slump cone test .Concrete slump test is
a measurement of concretes workability or fluidity. It is a method to point the consistency of
the concrete and indicate how much water has been used in the mix.
APPARATUS
 Slump Cone
 Scale for measurement
 Tampering Rod

Fig 5.8 Slump cone apparatus

PROCEDURE
1. The mould for the concrete slump test is a frustum of a cone of 300mm height and
base of 200mm in diameter and has a smaller opening at the top of 100mm.

2. The basis placed on a smooth surface and the container is filled with layers and
tampered with tampering rod (of standard 16mm diameter steel rod) for 25 times for
each layer.

3. When mould completely filled with concrete, the top surface is struck off (leveled
with mould top opening) by means of screening and rolling motion of tampering rod.

4. The mould must firmly held against its base during the entire operation so that it
could not move due to the poring of concrete.

33
5. Immediately after filling is completed and the concrete is leveled, the cone is slowly
and carefully lifted vertically an unsupported concrete will now slump.

6. The decrease in the height of centre of the slumped concrete is called slump.

7. The slump is measured by placing the cone just besides the slump concrete and the
tampering rod is placed over the cone. So that it should also come over the area of
slumped concrete.

8. The decreasing the height of the concrete to that of mould is noted with the scale.

34
5.4 COST ANALYSIS

5.4.1 Conventional concrete

For 1m3 of M25 grade of concrete (1:1:2), cost analysis is as follows:

 Quantity of cement = (1/4)×1.54×1440= 554.4kg

=11 bags
 Cost of cement = 300×11= 3300
 Quantity of fine aggregate =554.4kg
Cost of sand = 0.554×1800=998
 Quantity of coarse aggregate =1109 kg
Cost of coarse aggregate= 1.109×780
= 865

Total cost of M25 Grade concrete for 1m3 = Rs.5,163

5.4.2 Flexible concrete

For 1m3 of flexible grade of M25, cost analysis is as follows:
Mix ratio = 1:1 (cement: sand) and 1.2% fiber content
 Cement content= 548.6 kg =10.97 bags
Cost of cement =3292
 Fly ash content=548.6kg
Cost of fly ash=0.5486×1400= 768
 Fine aggregate content= 1097kg
Cost of fine aggregate =1.097×1800= 1974
 Fiber content = 1.2% of total volume
= 16.64 kg
Cost of fibers= 16.64×320=5324.8
 Amount of super plasticizer = 6ml/kg of binder
=6×1097=6.6 liters
Cost of super plasticizer = 40×6.6
=310
Total cost of flexible concrete for1m3 = Rs.11,668

35
 CHAPTER 6
RESULTS

6.1 Compressive strength of concrete:

Table 6.1 Results of compressive strength of concrete for 7 days

(7 days) in N/mm2
Fiber content Average of
(%) Cube 1 Cube 2 Cube 3 3 Cubes

0 19.87 20.04 19.83 19.91

1 23.51 24.08 23.70 23.78
1.2 24.52 23.94 24.16 24.20

Compressive strength( 7days)

30

25
Compressive strength (MPa)

20

15

10

0
0 1 1.2
Fiber %

Fig 6.1 compressive strength for 7 days

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 Table 6.2 Results of compressive strength of concrete for 14 days

Fiber content (14 days) in N/mm2

Average of
(%) Cube 1 Cube 2 Cube 3 3 Cubes

0 25.77 24.11 24.87 24.91

1 25.4 25.60 25.42 25.87
1.2 25.62 26.24 27.89 26.58

Compressive strength( 14 days)

30
Compressive strength (MPa)

25

20

15

10

0
0 1 1.2
Fber %

Fig 6.2 Compressive strength for 14 days

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 Table 6.3 Results of compressive strength of concrete for 28 days

FIBRE (28 days) in N/mm2

Average of
CONTENT
Cube 1 Cube 2 Cube 3 3 Cubes
(%)

0 28.47 28.92 29.22 28.66

1 29.73 29.42 29.64 29.6
1.2 31.42 30.86 32.48 31.58

Compressive strength ( 28days)

35

30
Compressive strength (MPa)

25

20

15

10

0
0 1 1.2
Fiber %

Fig 6.3 Compressive strength for 28 days

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6.2 Tensile strength of concrete:
Table 6.4 Results of tensile strength of concrete for 7 days

(7 days) in N/mm2
Fiber Average of
Content (%) Cube 1 Cube 2 Cube 3 3 Cubes

0 1.85 2.36 2.54 2.25

1 3.26 3.79 3.14 3.39
1.2 5.42 5.55 5.87 5.61

Split tensile strength (7 days)

6

5
Split tensile strength (MPa)

0
0 1 1.2
Fiber %

Fig 6.4 Split tensile strength for 7 days

39
 Table 6.5 Results of tensile strength of concrete for 14 days

(14 days) in N/mm2

FIBRE Average of
CONTENT Cube 1 Cube 2 Cube 3 3 Cubes

0 2.45 2.6 2.32 2.45

1 4.06 4.24 4.56 4.28
1.2 6.11 5.91 5.99 6.03

Split tensile Strength (14 days)

7

6
Split tensile strength (MPa)

0
0 1 1.2
Fiber %

Fig 6.5 Split tensile strength for 14 days

40
 Table 6.6 Results of tensile strength of concrete for 28 days.

(28 days) in N/mm2

FIBRE Average of
CONTENT Cube 1 Cube 2 Cube 3 3 Cubes

0 2.86 2.99 3.07 2.97

1 6.54 6.82 6.66 6.67
1.2 8.67 8.71 9.02 8.81

Split tensile strength (28 days)

10

8
Split tensile strength (MPa)

0
0 1 1.2
Fiber %

Fig 6.6 Split tensile strength for 28 days.

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6.3 SLUMP CONE TEST RESULTS

Table 6.7 Slump values

S. No Fiber content % Slump value (mm)

1 0 55

2 1 68

3 1.2 73

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 CONCLUSION
All the experimental data shows that the addition of polypropylene fiber improves the
physical and mechanical properties of the flexible concrete. Due to its high modulus of
elasticity the concrete can attain more flexibility when compared to conventional concrete.
From the above study it is concluded that bendable concrete will play a major role in
construction management to construction a structure to hold for so many years without any
failure. From the laboratory investigation the following are the conclusions are drawn.
 The use of Polypropylene fibers in the concrete brought out positive results satisfying
the required flexibility to the concrete.
 From the trials, it can be concluded that compressive strength and split tensile
strength increased with the addition of 1.2% fibers of total volume.
 From this experiment, we can say that flexible concrete is much tougher and has good
compressive strength for7 days, 14 days and 28days and the split tensile is much
better when compared to conventional concrete.
 The cost of flexible concrete is much higher than conventional concrete but it can be
minimized by using small cross section of member sizes and eliminating reinforcing
bars.

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 FUTURE SCOPE
1. ECC is a unique class of high-performance fiber-reinforced cementitious composites
featuring high tensile ductility and durability. However, the high cement usage in
ECC limits the material greenness and increases the material cost compared with
normal concrete. Iron Ore Tailings in powder form can be used to partially replace
cement to enhance the environmental sustainability of ECC.
2. Investigations and laboratory work to be done to find out Poisson’s ratio. It is
recommended that testing can be done on cylinders of concrete.
3. The application of concrete in earthquake resistant structures can be tested.
4. More laboratory work to be done to find out the corrosion resistance capacity of
concrete. Therefore, it is recommended that the testing can be done by casting ECC
Concrete beams with steel reinforcing bars.
5. The concrete canvas can also be made with the flexible concrete. The concrete canvas
is stronger and durable than the normal canvas. It can be used in the military area.
6. It can be used in roads and bridges. With the use of flexible concrete in roads and
bridges there is no need of joints such as expansion joint, contraction joint as the
concrete is itself have the ability to change its shape. Moreover the bridges and roads
are more durable and has low repair cost.
7. Impact loading can be applied to such a slab of ECC and the behavior can be studied
& be compared to conventional concrete.
8. Effect of temperature stresses on ECC can be studied.

44
 REFERENCES
1. Rangesh M. Jajodia, Prof.M. Nikhar “A study of flexible concrete sheet in civil
engineering.” International Journal of Innovative Research in Technology.
2. Dinesh [Link], Ajay [Link], Amol U. Gandhale, Shubham Fartade, Dipali
[Link] “Experimental study on flexible concrete by using polyurethane fibers”
International Journal of Trend in Scientific Research and Development.
3. S. Ooviya, [Link], [Link] ,[Link] “Experimental study on Flexible
Concrete.”International Journal for Research in Applied Science & Engineering
Technology.
4. Tushar R. Pati, [Link] “Flexible Behaviour of Concrete using Engineered
Cementitious Composite.” International Journal of Advance Engineering and
Research Development.
5. Balaji R. “Experimental study on ECC concrete” International journal of recent
scientific research.”
6. C. Neelaadharan, [Link], [Link] “Experimental Investigation on
Bendable Concrete by using Admixtures.” Suraj Punj Journal for Multidisciplinary
Research.
7. [Link].
8. [Link]

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