BAGASSE ASH AS PARTIALLY REPLACEMENT
FOR CEMENT IN CONCRETE
MINI PROJECT REPORT
Submitted To
DEPARTMENT OF CIVIL ENGINEERING
RAJIV GANDHI UNIVERSITY OF KNOWLEDGE TECHNOLOGY
RK VALLEY
By
CHINTHA NARAYANA SWAMY
R141390
Under the guidance of
[Link]. Ravi Yadla
DECLARATION
I certify that,
The work contained in this report has been done by us under the
guidance of “Ravi Yadla”. The work has not been submitted to any other institute for
any degree or diploma. I have confirmed to the norms and guidelines given in the
Ethical Code of Conduct of the Institute. Whenever I have used materials (data,
theoretical analysis, figures and text) from other sources, I have given due credit to
them by citing them in the text of the report and giving their details in the references.
Further, I have taken permission from the copyright owners of the sources, whenever
necessary.
Date:
Place:
1
CERTIFICATE
This is to certify that the third year report entitled “Under ground transportation of
metro system”, submitted by [Link] Prasad(R141945), [Link] swamy(R141390),
Shivashetti Manmath Rao(R141534), Arigela Swaraj(R141879) to Rajiv Gandhi University
of Knowledge Technology, is a record of bonafied mini project work carried out by him
under the “Ravi Yadla”.
Approved
Head of the Department
Faculty
External Examiner In-charge (T&P)
2
ABSTRACT:-
Sugarcane bagasse ash is a by product of the sugar factories found after
burning sugarcane bagasse which itself is found after the extraction of all economical
sugar from sugarcane. The disposal of this material is already causing environmental
problems around the sugar factories. Due to the boost of the construction activity in
the country, a huge shortage is created in most of the construction materials
especially cement, resulting in steady increase of price. This research was therefore,
conducted to examine the potential of bagasse ash as a cement replacing material.
Initially, bagasse ash samples were collected from Wonji sugar factory and its
chemical properties were investigated. The bagasse ash were then ground until the
particles passing the 63 μm reaches about 85%, which is similar to that of ordinary
Portland cement. Ordinary Portland cement and Portland pozzolana cement were
replaced by ground bagasse ash. Normal consistency and setting time of the pastes
containing ordinary Portland cement and bagasse ash from 5% to 30% replacement
were investigated. The compressive strength of mortars containing ordinary Portland
cement and Portland pozzolana cement with bagasse ash from 5% to 30%
replacements were also investigated. Four different concrete mixes with the bagasse
ash replacing 0%, 5%, 15% and 25% of the ordinary Portland cement were prepared
for 25MPa concrete with water to cement ratio of 0.55 and 350kg/m 3 cement
content. The properties of these mixes have then been assessed both at the fresh and
hardened state.
The results of the mortar work have shown that, up to 10% replacement of
the ordinary Portland cement by bagasse ash achieved a higher compressive strength
at all test ages i.e.7 and 28 days, whereas the 15% replacement of the cement by
bagasse ash in the concrete have shown a slightly lower compressive strength at 56
days. The water penetration depth was found to increase as the bagasse ash content
increases and all the blended concretes showed a higher maximum penetration depth
than the control concrete. It can therefore be concluded that 10% replacement of
cement by bagasse ash results in a similar concrete properties and higher replacement
could also be used with a slight reduction in the performance of the concrete.
3
CONTENTS
Chapter 1
1.1 Introduction
1.2 Methodology
1.3 Literature Review
Chapter 2
2.1 Materials and Methods
2.1.1 Cement
2.1.2 Aggregates
2.1.3 Water
2.1.4 Sugarcane Bagasse Ash
Chapter 3
3.1 Introduction to cement concrete
3.2 Properties of concrete
3.3 Scope of the work
Chapter 4
4.1 Preparation of Testing Specimens
4.2 Preparation of Specimens
4.3 Curing of the Specimen
Chapter 5
5.1 Testing of Specimens
5.2 Description of Compression Testing Machine
5.3 Tests conducted
Chapter 6
6.1 Results and Discussion
6.2 Test Results
6.3 Conclusions
6.4 References
4
CHAPTER-1
1.1 INTRODUCTION:-
Sugar production has emerged as one of the major agro industries all
over the world during the last few [Link] India sugar production is
undertaken practically throughout the country and there are well-established
large scale factories in 18 out of 29 States. According to the reports for the
last crushing season, there were 338 factories in operation which crushed
about 60 million tonnes of cane, producing 6.1 million tonnes of sugar and 2.5
million tonnes of molasses. Average bagasse production is about 30 percent of
the sugarcane crushed and about 90 percent of bagasse produced is used as
fuel. After controlled burning of bagasse,the ash obtained is known as bagasse
ash .Now a days,bagasse is also being used in the manufacturing of pulp and
paper products. Previous researches have shown that for each 10 tons of
sugarcane crushed; a sugar factory produces nearly 3 tons of wet bagasse
which is a waste product of the sugar cane industry.
It is the cellular and fibrous waste product after the extraction
of the sugar juice from sugarcane. Bagasse ash is a residue obtained from the
burning of bagasse in sugar producing factories. A good solution to the
problem of recycling of sugarcane residues would be by burning them in a
controlled environment and use the ashes (waste) for more noble means
(Ghavami et al., 1999).SCBA constitutes an environmental nuisance as they
form refuse heaps in areas when they are disposed off in low lying areas.
Western Maharashtra is having maximum number of sugar factories and these
factories are now facing disposal problem of large quantity bagasse. The
effective utilization of these waste products is a challenging task for a
researcher through economical and environmental friendly way.
The use of SCBA in concrete reduces the heat of hydration
and increases the life of structure. The reasons behind using this material in
concrete is that it contains large percentage of amorphous silica and
alumina ,which is responsible for secondary hydration, when SCBA comes in
contact with hydration products of cement and produces higher strength as
compared to conventional concrete due to formation of additional C-S-H gel
utilizing harmful lime produced during hydration. It has been found by various
researches that Bagasse ash is a valuable pozzolanic material similar to that of
slag, fly ash and ground granulated blast furnace ash (GGBS). Moreover usage
of bagasse ash in concrete helps in reduction of dead weight thereby producing
light weight structures.
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1.2 Methodology of Making Bagasse Concrete:-
After controlled burning of bagasse, the ash obtained (SCBA) is
Grinded and sieved through 150μ size sieve which provides fine bagasse ash
.SCBA so obtained was characterized for its physical and chemical properties in
pollution control board lab in pune. On the basis of characteristics of SCBA,
suitability of SCBA to be used for replacement of cement in concrete
production is accessed.
For experimentation M-25 controlled concrete using locally
available building materials (aggregates and sand) and OPC-53 grade cement is
used with suitable dose of admixture (Fosroc conplast SP500). Mix designing of
M-25 controlled concrete is done and results are validated by casting 8cube
samples (150cm×150cm×150cm) and subsequently testing it for compressive
strength after 7 days and 28 days.
After the above work cement is replaced by SCBA in the
ratio of 5%, 10%, 15%,20% in the concrete keeping same workability of
concrete. Twelve samples of each SCBA replacements are tested for 7 days and
28 days compressive strength .On the basis of experimentation it is observed
that about 12.5% replacement of cement by SCBA for M-25 concrete can be
done without changing the strength of concrete.
1.3 LITERATURE REVIEW:-
The cement and concrete technology has shown various advancements
during the past years. One of the best advancements is the use by-product
materials as a cement replacement to alleviate environmental and economical
impact of cement production. These cement replacing materials were reported
to improve different properties of the mortar and the concrete [2, 12,13, 27].
Bagasse ash is one of these by-product materials found from sugar factories.
Recently it has been studied for its feasibility as a cement replacing material
in some parts of the world and has been found to improve some of the
properties of mortar and concrete. The performance of mortar and concrete is
assessed by different tests on both the fresh and hardened [Link]
include workability, strength and permeability. This chapter is, therefore,
dedicated in discussing about cement, different performance criteria of
concrete, pozzolans and bagasse ash.
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CHAPTER-2
EXPERIMENTAL INVESTIGAITON:-
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. The details of experimental investigations are as follows.
2.1 Materials and Methods:-
2.1.1 Cement:-
In this experimental work Ordinary Portland cement (Grade53) conforming
to IS 12269-1987 in all trial mixes is [Link] physical properties of the
cement obtained on conducting appropriate tests conforming to process laid
down in IS: 269/4831 has been performed. The results are mentioned in table
1 shown below
Table 1: Physical properties of cement
S. No Property of cement value
1 Fineness of
cement(m2/kg) 320
2 Specific gravity of
cement 3.15
3 Standard consistency of
cement 35%
4 Initial setting time 90 mins
5 Final setting time 265 mins
6 Grade of cement(OPC) 53 grade 0pc
7
2.1.2 Aggregate:-
Fine Aggregate
Fine aggregates used were available on site and are tested, the results are
as per Indian standards BIS: 383: 1970. Specific gravity of fine aggregate is
2.94. These are used in replacement to river sand. Use of fine aggregate
improves the compressive strength of concrete. The aggregates to cement ratio
usually varies between 4:1 to 5:1. Use of fine aggregates provides better
bonding or interlocking of both fine and coarse aggregates.
Coarse Aggregate
The aggregates used were 20mm nominal maximum size and are
tested as per Indian standards and the results are within permissible limits
(BIS:10262, BIS: 383). The specific gravity of coarse aggregate is 3.09.
Aggregates should be kept moist or wet when high temperature is expected, If
wet aggregates are used absorption and moisture must be considered. Improper
amount of free water can lead to excess drying or improper compaction.
Adversely too much of water will make the paste or mortar too thin and
improper bond between aggregates and allowing paste/mortar seepage. The
paste/mortar will result in lower permeability rates of system.
2.1.3 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.
2.1.4 Sugarcane Bagasse Ash:-
Sugarcane bagasse ash which is obtained after burning of sugarcane it is a
waste product which can be useful as partially replacing cement due various
chemical [Link] ash contains 40-50% moisture at the time of
collection from factory. Bagasse is by product which burnt to generate
power required for different activities in [Link] of sugarcane bagasse ash
as a replacement material to cement improves the quality and reduce the cost
of construction. Sugarcane Bagasse Ash (SBA) is used as mineral admixture as
it has high silica content, thereby helps in increasing the strength of concrete.
Reduces the setting time of concrete as it has some properties of admixture
due to presence of sugar content in SBA.
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Table 2:Chemical properties of sugarcane bagasse ash
CHEMICAL COMPOUND % CONTENT
Silica 68.42
Aluminium Oxide 5.812
Ferric Oxide 0.218
Calcium Oxide 2.56
Phosphorous Oxide 1.28
Magnesium Oxide 0.572
Sulphide Oxide 4.33
Loss on Ignition 15.90
9
CHAPTER-3
3.1 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 [Link] 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 greater strength with age. Concrete possess a high
compressive strength and has a poor tensile strength. It also develops
shrinkage stresses.
3.2 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 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.
3.3 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 M25grade of concrete.
2. Casting of concrete cubes of M35 grade of concrete with different
percentages of SUGARCANE BAGASSE ASH (0%, 5%, 10%, 15%,20%)
3. Cubes are subjected to normal curing
4. Testing of specimens at various ages.
5. Plotting graphs and comparing the compressive strengths of
sugarcane bagasse ash blended concrete cubes in normal curing.
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CHAPTER-4
Sugar cane bagasse ash preparation:
4.1 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.
4.2 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.
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4.3 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 solution.
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CHAPTER-5
5.1 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
5.2 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
140kg/[Link]/min is maintained.
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5.3 TESTS CONDUCTED:
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 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 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.
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CHAPTER-6
6.1 RESULTS AND DISCUSSIONS:
Compressive strength Results:
% of SBCA 7 Days (Mpa) 28 Days (Mpa)
0 19.84 31.85
5 22.07 32.88
10 24.99 35.04
15 17.92 24.58
20 15.82 23.25
6.2 Graphs
Compressive Strength
N/MM^2
Time Period
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6.3 Test results:
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
6.3CONCLUSIONS:
The results shows that Sugarcane Bagasse was added in M25 grade concrete in
10%, 20%, 30%, 40% replacement from this experimentation we have obtained
various results of compressive strength was increased at 10% for M25 grade
concrete as compared to ordinary concrete. SBA partially in concrete increase
the workability of concrete as compared to ordinary concrete. The compressive
strength of concrete is achieved at 7 th day as compared to ordinary one. The
results for compression concluded that SBA can be used partially in concrete at
10% [Link] was seen that due to use of artificial sand in concrete the
strength achieved was less due to the brittle property of artificial sand for split
tensile. Use of SBA in concrete also reduces overall co2 emission from concrete
which is satisfactory. As the workability of concrete is increased therefore use
of super plasticizer is not essential. Concrete mix can be made effective using
the sugar industrial waste as it provides to be cheaper or economical for the
cost of construction. It reduces of about 10% cost for 1m3 concrete production.
Utilization of sugarcane bagasse ash in concrete also overcomes the problem of
the disposal of the waste produced by the sugar industries. Due to the light
weight property of the bagasse ash the density of the concrete mix is reduced.
6.4 REFERENCES:
1. [Link]. Kumar, Krishna Rao B.(2014), (IJIRSET), vol.3,issue 3, ISSN:
2319-8753 “A Study on Strength of Concrete With Partial Replacement Of
Cement With Quarry Dust And Metakaolin”.
2. K. Akhilesh Reddy & I. Siva Kishor (2017) (IJCIET) Vol.8 Issue 1 pp.847-
851“Study on Behaviour of Partial Replacement of Cement With Sugarcane
Bagasse Ash for High Strength Concrete Mix ”
[Link], Prof. Maneeth P.D.,Prof. Brij Bhushan S., [Link] S. Gurav,
(2016), (IJSRD) vol3, issue11,ISSN:2321-0613 “Experimental Investigation on
Partial Replacement of Cement by Sugar Cane Bagasse Ash inCement Concrete”
18