A mini Project Report On

STUDY ON FIBER REINFORCED CONCRETE WITH

MEMBRANE CURING
Submitted for partial fulfillment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY IN

CIVIL ENGINEERING

BY

[Link] 17K85A0115

[Link] 17K85A0127

[Link] REDDY 17K85A0116

[Link] 16K81A0174

UNDER THE GUIDANCE OF

MR. [Link] VIGNAN

Assistant Professor
Department of Civil Engineering

St. Martin’s Engineering College

An Autonomous Institute
A Non Minority College | Approved by AICTE | Affiliated to JNTUH, Hyderabad | NAAC-Accredited ‘A+’ Grade
| 2(f) & 12(B) status (UGC) ISO 9001:2008 Certified | NBA Accredited | SIRO (DSIR) | UGC-Paramarsh |
Recognized Remote Center of IIT, Bombay

Dhulapally, Secunderabad – 500100.

November, 2019

1
 St. Martin’s Engineering College
An Autonomous Institute
A Non Minority College | Approved by AICTE | Affiliated to JNTUH, Hyderabad | NAAC-
Accredited ‘A+’ Grade | 2(f) & 12(B) status (UGC) ISO 9001:2008 Certified | NBA Accredited |
SIRO (DSIR) | UGC-Paramarsh | Recognized Remote Center of IIT, Bombay

Dhulapally, Secunderabad – 500100

Certificate

This is to certify that the project work entitled “STUDY ON FIBER

REINFORCED CONCRETE WITH MEMBRANE CURING” that is

submitted by

[Link] 17K85A0115

[Link] 17K85A0127

[Link] REDDY 17K85A0116

[Link] 16K81A0174

in partial fulfillment for the award of degree of Bachelor of technology in CIVIL

ENGINEERING is a record of bonafide work carried out by them. The results embodied
in this report have been verified and found satisfactory.

Faculty in charge, External Examiner Head of the Department

Mr .G. Siva Vignan, Dr. G. Venkata Ramana,
Assistant Professor, Professor& HOD,
Department of Civil Engineering Department of Civil Engineering
SMEC. SMEC.

i
 Acknowledgement

The satisfaction and euphoria that accompanies the successful completion of any
task would be incomplete without mention the people who made it possible and whose
encouragement and guidance have crowded our efforts with success.

We extend our deep sense of gratitude to Dr. P. SANTOSH KUMAR PATRA,

Principal, St. Martin’s Engineering College, Dhulapally, for permitting us to undertake
this project.

We are also thankful to Dr. Dr. G. Venkata Ramana, Head, Department of

Civil Engineering, St. Martin’s Engineering College, Dhulapally, for his support and
guidance throughout our project and faculty In charge Mr .G. Siva Vignan , Assistant
Professor, in Civil department for his valuable support.

We would like to express our sincere gratitude and indebtedness to our project
Coordinator Mr .G. Siva Vignan, [Link] ,Structural Engineering, St. Martin’s
Engineering College, Dhulapally, for his support and guidance throughout our project.

Finally, we express thanks to all those who have helped us to complete this
project successfully. Furthermore, we would like to thank our family and friends for
their moral support and encouragement.

[Link] 17K85A0115

[Link] 17K85A0127

[Link] REDDY 17K85A0116

[Link] 16K81A0174

ii
 DECLARATION

We [Link], [Link], [Link] REDDY and [Link] here by

declare that the report of the Mini Project work entitled “STUDY ON FIBRE
REINFORCED CONCRETE WITH MEMBRANE CURING “which is being
submitted to the St. MARTIN’S ENGINEERING COLLEGE Hyderabad, in partial
fulfillment of the requirement for the award of Degree of BACHELOR OF
TECHNOLOGY, is a bonafide report of the work carried out by us. The material
contained in this report has not been submitted to any University or Institution for the
award of any degree.
Place: SMEC, HYDERABAD
Date:

([Link]-17K85A0115)

([Link] -17K85A0127)

([Link] REDDY -17K85A0116)

([Link] -16K81A0174)

iii
 ABSTRACT
The concept of using fibers in concrete to improve resistance to cracking
and fragmentation is old and intuitive. During the last 30 years’ different types of fibers
and fiber materials were introduced and are being continuously introduced in the market
as new applications. In this project, Polypropylene is used to study its effects in
reinforcing concrete mixes and to obtain basic strength. The compressive, flexural
strength tests were performed by using fiber weight content from 5%. As a result, it was
found that the use of polypropylene fiber considerably increases the tensile strength as
the fiber content is increased. The compressive strength has remained almost same with
5% of fiber. Eventually it was observed that, there was an increase in Flexural strength
for about 45%.
Curing must be undertaken for reasonable period of time if the concrete is to
achieve its potential strength and durability. Efficient uninterrupted curing is the key to
quality concrete. In this project, we have also done the Curing by preventing excessive
loss of moisture from the concrete either by leaving formwork in place covering the
concrete with impermeable membrane after the formwork has been removed by the
application of suitable chemical curing agent (water based) by combination of such
methods Curing by continuously wetting the exposed surface prevents the loss of
moisture from it.
Key Words: Fiber Reinforced Concrete, Compression Strength, Flexural
Strength, Membrane curing

iv
 CHAPTER: 1
INTRODUCTION

[Link]:

Concrete is one of the most versatile and has been leading building materials. It can be
casted in to fit any structural shape as shown in fig 1.1 . It is readily available in urban areas
simply at an affordable cost. Though, Concrete is strong under compression but weak under
tension. The advantages to using concrete include high compressive strength, good fire
resistance, high water resistance, low maintenance, and long service life. The disadvantages
to using concrete include poor tensile strength, and formwork requirement.

(Fig 1.1: Fresh concrete and Hardened Concrete)

It is also relatively brittle material. To add tension property to concrete, Reinforcement

is added to concrete as shown in fig 1.2 . Tensile strength of concrete is typically varying
around 8% to 15% of its compressive strength. This weakness has been dealt with over
many decades by using a system of reinforcing bars to create reinforced concrete; so that
concrete primarily resists compressive stresses and steel bars resist tensile and shear
stresses.

1
 (Fig 1.2: Reinforced Concrete)

Fiber-reinforced concrete (FRC) is concrete containing fibrous material which increases its
structural integrity. These fibers act as an alternative material to the reinforcing materials
like HYSD Bars. This concrete contains short discrete fibers that are uniformly distributed
and randomly oriented as shown in fig 1.3. Fibers include steel fibers, glass fibers, synthetic
fibers and natural fibers – each of which lend varying properties to the concrete. In addition,
the character of fiber-reinforced concrete changes with varying concretes, fiber materials,
geometries, distribution, orientation, and densities.

(Fig 1.3: Fiber Reinforced Concrete)

Curing is the process of controlling the rate and extent of wetness loss from concrete
during cement hydration. It may be placed in position during the manufacture of concrete
products, thereby providing time for the hydration of the cement to occur. Since the hydration

2
of cement does take time, days, and weeks rather than hours, curing must be undertaken for
reasonable period of time if concrete is to achieve its potential strength and durability. Curing
may also encompass control of temperature since this affects the rate at which cement
hydrates. Curing, is a process of controlling the rate and extent of moisture loss from concrete
during cement hydration. In order to obtain good quality concrete, an appropriate mix.
Curing must be undertaken for reasonable period of time if the concrete is to achieve its
potential strength and durability. Curing is essential if concrete is to perform its in-tended
function over the design life of the structure whereas; excessive curing time may lead to the
rapid up construction cost of the project and unnecessary delays. Curing embraces the control
of temperature as it affects the hydration rate in cement. If within the curing period, natural
temperatures of concrete are in the acceptable range of values, then only moisture content
needs to be controlled. If the natural temperature is outside the acceptable range of values,
some mean sill be required for controlling the temperature of concrete. The curing of concrete
is performed both at normal and elevated temperatures also.

[Link] Statement:

 As we know that concrete is good in compression and weak in tension. To

increase we are using reinforcement in concrete.

 Introducing of reinforcement in concrete will increase its self-weight of the

structure.
 The amount of water used for curing of concrete is very high

[Link]:

 To analyze the properties of Fiber reinforced concrete

 To study the effect of using polypropylene fiber on concrete compressive and
split tensile strength.
 To reduce the usage of reinforcement in R.C.C.
 To eliminate the water used for curing of concrete.
 To increase the Flexural strength of concrete.

3
[Link]:

Concrete is a composite material consisting of Cement, Aggregates (Fine and

Coarse) as shown in fig 1.4 and water in suitable proportions. The chemical interaction
between cement and water binds the aggregates in to a solid mass. Fresh concrete will
be plastic, so that it can be molded to any desired shape in the moulds and compacted
to form a dense mass.

(Fig 1.4: Materials used in concrete)

Water has to be applied for few days over the concrete surface soon after its setting
because the Hydration reactions between cement and water will continue for a longer
period due to which hardening of concrete takes place. This period over which concrete
is kept moist during which concrete gains strength is called curing period. Hence, the
strength of concrete increases with age.

The process of solidification of concrete from plastic stage is called setting while
gaining of strength after setting called hardening. Usually, setting completes with in
maximum duration of 10 hours, which about 90% of hardening is completed by 28 days.
The properties and quality of cement concrete are influenced by the properties of its
ingredients and quality control maintained during its making and curing. Hence, it is
necessary to study the properties of ingredients of concrete.

Concrete structures have become very common in Civil engineering construction.

Concrete has established as universal building material because of its high compressive

4
 strength, its adoptability to take any form of shape, resistant to fire and corrosion, and
abundant availability of its constituent materials with negligible maintenance cost.
Concrete is utilized in building structures in the form of plain concrete, reinforced
concrete and pre-stressed concrete. It is estimated that the global production of concrete
is at an annual rate of 1m3 (approximately 2.5 tones) per capita(Neville 2003). The
global consumption of natural aggregate(NA) will be in the range of 8-12 billion tones
after 2020.

1.4.1. History of Concrete:

The word concrete comes from the Latin word“Concretus” (meaning compact
condensed), the perfect passive participle of “concrescere” from “Con-” (together) and
“crescere” (to grow).Concrete was used for construction in many ancient structures.
During the Roman Empire, Roman concrete (or opuscaementicium) was made from
quicklime, pozzolana and an aggregate of pumice.

Its widespread use in many Roman structures, a key event in the history of
architecture termed the Roman Architectural Revolution, freed Roman construction
from the restrictions of stone and brick material and allowed for revolutionary new
designs in terms of both structural complexity and dimension. The widespread use of
concrete in many Roman structures has ensured that many survive to the present day.
The Baths of Caracalla in Rome are just one example. Many Romana queducts and
bridges have masonry cladding on a concrete core, as does the dome of the Pantheon.
Some have stated that the secret of concrete was lost of 13 centuries until 1756, when
the British engineer John Sematon pioneered the use of hydraulic lime in concrete, using
pebbles and powdered brick as aggregate as shown in fig1.5.

5
 (Fig 1.5: Baths of Caracalla)

1.5 Advantages of Concrete:

 Concrete is Economical

 Concrete Hardens at Ambient Temperature

 Ability to be cast into Shape

 Energy Efficiency in Production

 Excellent Water Resistance Characteristics

 High-temperature resistance

 Ability to Consume and Recycle Waste

 Application in Reinforced Concrete

 Low or Zero Maintenance Required

 Multi-Mode Application

6
1.6 Disadvantages of Concrete:

 Concrete is Quasi-brittle Material

 Low Tensile Strength

 Concrete has Low Toughness
 Concrete has Low specific strength
 Formwork is Required
 Working with cracks
 Required large amount of water for curing
 Demands Strict Quality Control
 Dead load of reinforced concrete is high

1.7 Polypropylene Fibers:

Recron 3s Fibers are Engineered Micro Fibers with a unique “Triangular” Cross-
section, used in Secondary Reinforcement of Concrete. It complements Structural Steel
in enhancing Concrete's resistance to Shrinkage Cracking and improves mechanical
properties such as Flexural / Split Tensile and Transverse Strengths of Concrete along
with the desired improvement in Abrasion and Impact Strengths.

Recron 3s Fibers are manufactured in an ISO 9001:2000 facility for use in

Concrete as a “Secondary Reinforcement” at a rate of dosage varying from 0.1% to
0.4% by volume (0.9Kgs/Cu.M —3.60Kgs/Cu.M ). Fibers comply with ASTM C 1116,
Type 111 Fiber Reinforced Concrete.

Recron 3s Fibers are Engineered Micro Fibers with a unique “Triangular” Cross-
section, used in Secondary Reinforcement of Concrete as shown in fig 1.6. It
complements Structural Steel in enhancing Concrete's resistance to Shrinkage Cracking
and improves mechanical properties such as Flexural / Split Tensile and Transverse
Strengths of Concrete along with the desired improvement in Abrasion and Impact
Strengths.

7
 Recron 3s Fibers are manufactured in an ISO 9001:2000 facility for use in
Concrete as a “Secondary Reinforcement” at a rate of dosage varying from 0.1% to
0.4% by volume (0.9Kgs/m3 —3.60Kgs/m3 ). Fibers comply with ASTM C 1116, Type
111 Fiber Reinforced Concrete.

(Fig 1.6: Polypropylene Fibers)

1.8 Membrane Curing:

Membrane curing is an advanced and a special type of curing using

ROOFEXCURE WB recommended wherever transparent coating required.

Features & Benefits

Single application: Forms moisture barrier for whole of the curing period. No
other curing necessary: Eliminates use of water, Hessian or sand, completely. Reliable:
No risk of erratic or poor curing and ensures that cement hydrates efficiently. Ensures
hard wearing surface. Minimizes risk of drying shrinkage cracks and dusty surfaces as
shown in fig 1.7. Easy and safe spray application: Non-toxic and non-flammable

Drying Time: Less than one hour.

8
 Provides a acrylic blended, white pigmented curing membrane for new concrete.

 Compatible with many paints, adhesives, and resilient floor coverings.

 Seals concrete surfaces to protect from the effects of weathering.

 Helps eliminate dusting and hardens concrete surface by promoting proper cement
hydration. Resistant to yellowing.

(Fig 1.7: Membrane Curing)

CHAPTER:2

9
 Literature review

Dr. L. B. Zala, et al (2012) have worked on the concept of “Experimental

Investigations on Partial Replacement of Cement with Fly- Ash” and have stated
the following results:

The Compressive strength reduces when replacement of hypo sludge

percentage increases when compare to traditional concrete. Replacement of
cement with hypo sludge provides maximum compressive strength at 10%
replacement but it is lesser than traditional concrete. Flexural strength of beam
reduces when replacement of hypo sludge percentage increases when compare to
traditional concrete.

Dharani.N et al. (2013): have researched on the concept on “Experimental

Investigation On Mechanical Properties Of Recon 3s Fibers Reinforced
Hyposludge Concrete”and concluded the following results:

The authors found that The optimal replacement percentage of cement with
hyposludge is found to be 30% when Recron 3s fibers are not added. On addition
of Recron 3s fiber with cement matrix, the compressive strength and split tensile
strength decrease with increase in fiber content, however the flexural strength
increases with increase in fiber content.

Mr. R. Balamurugan, [Link] (2014): have worked on “experimental investigation

of partial replacement of cement by industrial waste(hypo sludge)” have declared
the following results

The authors further increase in hypo sludge reduces the strengths gradually.
If silica is added the strength will be considerably increased, because of lack of
silica in hypo sludge, considerably this type of Concrete, will be used for road

10
works effectively with less consumption of cement.

Dharani .N (2015): have experimented “A review on fiber reinforced

concrete”and concluded the following results:

The authors indicated that 10% replacement of cement with Hypo sludge
and 50% replacement of fine aggregate with Copper slag show increase in
compressive strength and flexural strength compared to other combinations. 10%
replacement of cement with Hypo sludge and 40% replacement of fine aggregate
with Copper slag show increase in split tensile strength compared to conventional
mix.

Nilesh K. Vasoya., et al (2015): have worked on “Utilization of various waste

materials in concrete”and had accomplished the following results:
He noticed that The industrial waste materials were found to be performing
better than normal concrete, in properties such as workability, durability,
permeability and compressive strength. Utilization of these wastes in concrete will
not only provide economy but also help in reducing disposal problems.

C. Patodi, C. V. Kulkarni (2012): have done the research on “ A review on fiber

reinforced concrete” and have concluded the following results:

They found that matrix having 0.3% of recron and 0.7% of steel fiber
volume fraction was found: More balanced in terms of strength and post – peak
ductility. Best resistance against impact and maximum toughness. For overall
better performance.

Raghunath and [Link](2008): has worked on “Effect of confinement on the

axial performance of fiber reinforced polymer wrapped column” and concluded
the following:

11
 They founded that Flexural behavior of high strength steel fiber reinforced
concrete beams by In this study total 4 beams of 3m length and 150mmx250mm
in cross section were casted and tested in laboratory. Three different steel fibers
volume were taken i.e. 0.5%, 1% and 1.5%. All beams were tested under two point
load condition in a loading frame of 750kn capacity.

[Link] Chandar And [Link](2018): have worked on experimental

investigation on “The mechanical properties of concrete mixed with banana stem
fiber as well as hybrid steel fiber” and concluded the following:

They reported that it was observed that both normal and steel reinforcement
concrete with deformation bars showing improved bond strength at the age of 28
days

Ankita [Link], Anand [Link], Feroz H. Khan(2017): have worked on

“Membrane curing of concrete” and concluded the following results:

The author reported that the membrane curing is done by using of chemical curing
compound (wax) [Link] membrane curing can achive the 90% of strength.

Gourav Gupta, Sameer Malhotra(2018) : have worked on “a case study on fiber

reinforced concrete” and founded the following:

The author reported that the compressive, splitting tensile strength tests were
performed by changing fiber weight content from 0% to 1% of the cement weight
content. As a result, it was found that the use of polypropylene fiber considerably
increases the tensile strength as the fiber content is increased.

Akinwumi, Gbadamosi, Z.O.(2014): have worked on “effects of curing

12
 condition and curing period on compressive strength” and concluded the
following:

He reported that the various Effects of Curing Condition and Curing Period
on the Compressive Strength Development of Plain Concrete

R. Sumanthi, Shyamala bhoomesh(2018): have worked on “The comparative

study between the compressive strength of traditional curing and accelerated
curing of concrete” have declared the following:

He Reported That from the experimental out comes it was concluded that
the immersion curing accomplished a mediocre strength.

CHAPTER:3

MATERIALS

The Primary Materials required for this process of Research are Cement, Fine Aggregate,
Course Aggregate, Water, and Polypropylene Fibers.

13
3.1. CEMENT:

Cement is one of the basic construction material that will be generally in powdered
form as shown in fig3.1 and hardens upon the addition of water to it. It can serve as a binding
material to aggregates to obtain strength. It possesses cohesive and adhesive properties. The
cement used for this research is Portland Pozzolana Cement of 53 Grade (As per Indian
Standards). The Specific Gravity is 2.71.

Portland Pozzolana cement is ordinary Portland cement intimately blended or inter

ground with pozzolanic materials such as fly ash, calcined clay, rice husk ash etc.

Portland cement clinker is either inter ground or intimately blended with specified
quantities of gypsum and pozzolanic materials to produce Portland Pozzolana cement.
Pozzolanas by themselves do not have cementitious properties but reacts with calcium
hydroxide in the presence of moisture at normal temperature to form compounds having
cementitious properties. The concrete produced by using Portland Pozzolana cement has
high ultimate strength, is more durable, resists wet cracking, thermal cracking and has a high
degree of cohesion and workability in concrete and mortar.

(Fig: 3.1: Cement)

The below table represents the different properties of cement like chemical and physical
properties
Table 3.1 Properties of Portland Pozzolana Cement(Fly Ash based):

Test Requirements of
Particulars
Results IS:1489-1991(Part1)

14
CHEMICALREQUIREMENT
S
X+(4.0(100-X))/100
Insoluble Material (%by mass) 22.80 (x = declaration% of Max
fly ash)

.Magnesia (% by mass) 1.07 6.00 Max

Sulphuric Anhydride (% by mass) 2.38 3.00 Max

Loss on Ignition (% by mass) 1.72 5.00 Max

Total Chlorides (% by mass) 0.035 0.10 Max

PHYSICAL REQUIREMENTS

Fineness (m2/kg) 390 300 Min

Standard Consistency (%) 33.5

Setting Time (minutes)

[Link]

[Link] 150 30 Min

225 600 Max

Soundness

Le-Chat Expansion (mm)

Max
Autoclave Expansion (%) 0.5 10.0
Max
0.025 0.8

Compressive Strength (MPa)

28.6 16 Min

15
 a.72 +/- 1hr.(3 days) 38.6 22 Min

58.0 33 Min
b.168 +/- 2 hr.(7 days)

c.672 +/- 4 hr.(28 days)

Drying Shrinkage (%) UT 0.15 Max

15.0 Min
% of Fly Ash addition 25.0
35.0 Max

3.2. AGGREGATES:

Aggregates are the most important elements for the concrete. They add shape, body
and strength to the concrete. They occupy about 70% of the Volume of concrete .They also
enhance the Bulk Density of Concrete.

3.3. FINE AGGREGATE:

The Aggregate passing through IS: 4.75 mm sieve could be called as Fine Aggregate
as shown in fig 3.2. Generally, Fine Aggregate is a filling material for the Concrete. The
Fine Aggregate used for this project is River Sand. The Specific Gravity of Fine Aggregate
is 2.4 to 2.6.

(Fig: 3.2: Fine Aggregate)

3.4. COARSE AGGREGATE:

16
 The Aggregate passing through IS: 20 mm sieve and retained on IS: 4.75mm sieve
could be called as Coarse Aggregate. Generally, Coarse Aggregate is a material that
enhances the strength and stability for the Concrete. The Coarse Aggregate used for this
project is from Miyapur Quarry as shown in fig 3.3. The Specific Gravity of Fine Aggregate
is 2.4 to 2.6.

(Fig: 3.3: Coarse Aggregate)

3.5. WATER:

Water is the main ingredient used to mix all the contents. Potable water is used
as usage of any other water may contain salts and cause decrease in strength of
concrete.

(Fig: 3.4: Potable Water)

17
3.6:POLYPROPYLENE FIBERS:

Recron 3s Fibers are manufactured in an ISO 9001:2000 facility for use in Concrete
as a “Secondary Reinforcement” at a rate of dosage varying from 0.1% to 0.4% by volume
(0.9Kgs/m3 —3.60Kgs/m3). Fibers comply with ASTM C 1116, Type 111 Fiber Reinforced
Concrete.

The below table represents the properties of fibers like Shape, Cut Length, Effective
Diameter, Specific Gravity etc

Table 3.2 Properties of Fibers:

POLYESTE POLYPROPYLE
S. No. Properties Units Remarks
R NE
1 Shape Triangular Triangular
+/- 1mm Project
specific
3/4.8/6/12/ customized
2 Cut Length mm 3/4.8/6/12/ 18/24
18/24 lengths can be
produced on
request
Effective
3 microns 20-40 25-40 -
Diameter
Specific
4 1.34-1.39 0.90-0.91 -
Gravity
Melting
5 Deg.C 250-265. 160-165
Point
*Estimated
tensile strength
Tensile a in Mpa 4-6
6 Gpd 4-6 * 4-6 *
Strength * Polyester 480-
730
Polypropylene

18
 320-490
7 Elongation % 20-60 60-90 Initial Modulus

Young's Tests done as

8 MPA > 5000 > 4000
Modulus per AC

Alkaline-
9 Very Good Very Good 32 standards
Stability

(Fig 3.5: Polypropylene Fibers)

PRIMARY APPLICATIONS

 Floorings / Grade Slabs

 Pavement quality Concrete

 Parking Slabs

 Foundations / Retaining Walls

 Roof Slabs

 Water Retaining Structures

19
  Shotcrete

 Bridge Decks/Overlays

Application rate:

The minimum application rate is 0.90Kgs/m3to achieve desired results and specific
to a particular application area. For application specific dosages, please contact our
representative for guidance.

Compatibility:

Recron 3s fibers are compatible with all commonly used admixtures in Concrete.

Packaging:

Recron 3s fibers are available in 125 Grams, 450 Grams, 600 Grams, 900 Grams and
1.35 Kgs plastic pouches. They are packed in cartons and palletized for protection during
transportation.

3.7. CURING COMPOUND:

WB is purely 100% Acrylic blended water I based concrete curing compound which
eventually having good bonding adhesion with the applied surface, Roofexcure WB can not
effected by natural weathering.

Roofexcure Tac:

Transparent Acrylic Blended water based concrete curing compound with same
features like ROOFEXCURE WB recommended wherever transparent coating required.

Appearance:

ROOFEXCURE WB - is an acrylic blended, white pigmented. After application and

drying, Roofexcure WB offers a highly bonded white colored appearance.

20
Coverage:

Textured Concrete: [Link].

Smooth Concrete: [Link]

Surface Preparation:

The concrete surface must be clean and free of standing water. l Remove any sealer
or other material that may prevent absorption of the ROOFEXCURE WB.

Areas of applications:

Interior and exterior concrete/mortar immediately after freshly laid.

Storage & shelf life:

ROOFEXCURE WB- has a shelf life of 2 years when stored at temperatures between
5°C and 35°[Link] should be kept airtight to prevent surface evaporation.

Packing

Available quantity in market are 1, 5, 10, 20, 30 & 210 Ltrs Pack.

21
 CHAPTER:4

METHODOLOGY

4.1. Designing Procedure for M25 Grade Concrete:

 Grade of concrete = M25 grade

 The proportions are 1:1:2

(cement : fine aggregate : coarse aggregate)

 % of polypropylene fibers = 5% of the cement weight

 Water/cement ratio = 0.5

 Amount of water added = (wt. of the cement+% of polypropylene fibers)*0.5

Quantity of materials for casting single cube and Beam:

The below table represents the quantity of materials required for casting 1 beam and 1
cube.

Table: 4.1: Quantity of materials for casting single cube and Beam

DESCRIPTION BEAM CUBES

Dimensions 500*100*100mm 150*150*150mm

Quantity of cement 3.150kg 2.100kg
Quantity of fine aggregate 3.000kg 2.000kg
Quantity of coarse aggregate 6.000kg 4.000kg
Quantity of polypropylene 0.150kg(5%) 0.100kg (5%)
fibers
Amount of water 1.650 liters 1.100 liters

22
4.2. Batching of materials:

Batching is the process in which the quantity or proportion of materials like

cement, aggregates, water, etc. are measured on the basis of either weigh or volume to
prepare the concrete mix. Proper Batching improves the workability of concrete by
reducing the segregation or bleeding in concrete. It helps to get a smooth surface of the
concrete. It also increases the speed of construction and minimizes the wastage of
concrete ingredients. Hence, batching of concrete is an essential process while making
concrete.

Once concrete mix design is carried out, the first task is batching of concrete
materials like cement, aggregates, admixture, etc. The batching of concrete is done by
measuring and combining required concrete ingredients either by weight or by volume
as per the mix design.

4.2.1. Volume Batching of Concrete Ingredients:

Volumetric batching of concrete is done by using measurement boxes, locally

known as “farmas” or “gauge boxes”. In an ideal case, the volume of the farma is made
equal to the volume of one bag of cement i.e., 35 liters or multiple thereof. Concrete
ingredients like fine aggregates (sand), Coarse aggregates are measured by farmas or
gauge boxes. Care must be taken to see that the farmas or gauge boxes are not overfilled.
In volumetric batching, water is measured either in Kg or liters. To measure the quantity
of water, the water meter is used while batching or use cans of water having the fixed
volume.

4.2.2. Weigh Batching of Concrete Ingredients:

In weigh batching, the proportion of concrete ingredients is decided by the

weighing. It is done either by using “weighing machine” or by other equivalent
weighing systems as shown in fig4.1.

23
 Weigh batching system facilitates simplicity, flexibility and accuracy. Water is an
essential constituent and hence using optimum water is must. Less water would make
concrete unworkable while excess water will reduce the strength of concrete. Water
must be measured accurately in liters.

Disadvantages of Poor Batching of Concrete Ingredients:

 Poor batching of concrete ingredients directly impacts the strength of concrete.

Because of poorly batching, concrete ingredients never mix homogeneously and
therefore workability will suffer.
 Poorly batched concrete ingredients may result in the formation of voids in the
concrete which leads to honeycombing.
 Poor batching also results into porous concrete which becomes the reason of leakages
in the house.
 The porous concrete may be the reason of corrosion and will ultimately reduce the
life of the structure and increase the cost of repairs.
Traditionally batching of concrete is done by volume. Batching accuracy is
important. It is however preferred to do weigh batching rather than volume
batching. Volume batching may be allowed only where weigh batching is not
practical. It is always advisable to spend little bit extra on the concrete mix design
and follow all the batching process recommended by the designer, as in the long
term, it will saves you a fortune. For this project, we have adopted weigh batching.

24
 (Fig 4.1: Batching of materials)

4.3. Mixing:

Mixing is the most important activity that has to be carried out for the concrete.
The performance and other characteristics are totally depended on the mixing. The
quality of the concrete also gets decided by the homogeneity of mix during the mixing
and the placement of the material. For this project, we have adopted hand mixing for
concrete. Hence, concrete has to be mixed properly by following the below sequence of
operations:

Process for Hand Mixing of Concrete:

 All the materials will be weighted as per the mix design.

 Before the mixing begins, the surface of the mixing tray will be cleaned with a dry
cloth.
 Aggregates are added in the tray and mixed thoroughly. (First Coarse then Fine
Aggregate will be added)
 Cement will be added into the aggregates in the tray, and the mix will be made
uniform.
 Water will be added into this mixture slowly while the mixing of aggregate and
cement is going on as shown in fig 4.2.

25
  Concrete is mixed for up to 5 minutes after the water is added. Till a uniform and
homogenous form arrives
 Then the concrete will be proceeded for further operations

(Fig 4.2: Mixing of Concrete)

4.4. Placing, Compaction, Hardening of Concrete specimens :

After, the concrete is mixed, it will be tested in the Slump Cone and Compaction
Factor apparatus to determine its Workability (if required). After that Placing,
Compaction and other sequence of operations will be followed. Let us see about them.

4.4.1. Placing of Concrete :

Before placing the concrete in the moulds, they have to be greased or oiled
properly as shown in fig 4.3. This provides us the ease of Concrete specimens stripping.
Special care has to be taken during oiling the moulds, so that no concrete stains are left
on the moulds. Concrete is placed in moulds of 150*150*150mm cubes and beams
500*100*100mm size and concrete is introduced in them by using trowel in 3 layers.

26
 (Fig 4.3: Preparation of specimen and placing of concrete)

4.4.2. Compaction of Concrete :

Compaction of Concrete releases any entrained air voids contained in the fresh
concrete. If the concrete specimens are not properly compacted in a proper manner, then
the maximum strength of concrete cannot be achieved.

After the concrete is placed in the moulds they have to be tamped in each layer
for about 25 blows by using tamping rod as shown in fig 4.4. Then this concrete is
placed on Vee-Bee Compaction Device, where mechanical vibrations are provided, this
gives additional Compaction ensuring better surface finish and minimizes voids as
shown in fig 4.4.

After this vibration, the top surface of the cube is smoothened using a
trowel to get a smooth surface finish.

27
 (Fig 4.4: compaction )

4.4.3. Hardening of Concrete :

The concrete moulds are left to open atmosphere for 18-24 hours so that the
concrete will get hardened . Then the concrete cubes are removed from the moulds as
show in fig 4.5 and applied the curing compound for 7, 14 ,28 days.

(Fig 4.5: hardened concrete, un moulding)

28
4.5. Curing of Concrete :

Curing is the process of keeping concrete surface moist soon after the hardening
of concrete. It will be done to lower the heat evolved during Heat Of Hydration and to
control cracks.

Types of Curing :

1) Curing by Ponding

2) Curing by Gunny bags

3) Curing by Moisture Guns

4) Curing by providing a Curing Membrane

For this project, we have adopted the Membrane Curing for 7, 14, 28 days after
Un-molding of Cubes and proceeded for further tests

4.5.1. Process of applying membrane curing compound to cubes &beams:

[Link]. When to apply

The compounds should never be applied to dry surfaces since these will absorb
the compound, and staining or discoloration may result. If the surface is dry, that is a
sign that the curing has been left too late. On vertical surfaces, apply the compound -
standard or high-grade-almost immediately after the formwork has been stuck as shown
in fig 4.6. If the surface has dried out, wet it down with clean water then spray while it
is still moist. On slabs, apply the compound as soon as possible after any bleed water
has evaporated, and certainly no later than half an hour after the sheen caused by the
water has gone. Curing compounds do not work if sprayed on top of water. In damp
conditions the water may take a few hours to disappear, but much less on a dry day.

29
[Link]. Using the Compounds

There are various points to watch when you are applying a curing compound.
Before you start, make sure that you have enough stock in for the job in hand- you will
need about a liter for each 4 of surface area - and sufficient cleaning solvent, too.

Always wear protective goggles, gloves and mask. You should avoid getting the
compound on your skin, in your eyes or in your mouth, for it might cause harm. Make
sure you read and understand the manufacturer's health and safety notes so that you will
know what to do if anything goes wrong. Stir the compound before use, especially if it
is a pigmented one, since the pigments tend to settle at the bottom of the drum. Fill the
spray reservoir with the compound, then you can start work. You should hold the spray
about 300 to 500 mm from the surface, preferably even closer when there is a wind

In windy conditions, the roller application illustrated to the right is the preferred
option. It is vital that you cover all the concrete, and with a uniform layer. This is best
ensured by first moving the nozzle back and forth to apply half the quantity required,
then applying the remainder by moving the nozzle at right angles to the initial strokes.

Liquid membrane compound consisting of waxes, resins, chlorinated rubber, and

other materials can be used to retard or reduce evaporation of moisture from concrete.
They are the most practical and most widely used method for curing not only freshly
placed concrete but also for extending curing of concrete after removal of forms or after
initial moist curing. However, the most effective methods of curing concrete are wet
coverings or water spraying that keeps the concrete continually damp. Curing
compounds should be able to maintain the relative humidity of the concrete surface
above 80% for seven days to sustain cement hydration.

Membrane curing compound are of two general types: clear, or translucent; and
white pigmented. Clear or translucent compounds may contain a fugitive dye that makes
it easier to check visually for complete coverage of the concrete surface when the
compound is applied. The dye fades away soon after application.

30
 Curing compounds should be uniform and easy to maintain in a thoroughly mixed
solution. They should not sag, run off peaks, or collect in grooves. They should form a
tough film to withstand early construction traffic without damage, be non-yellowing,
and have good moisture-retention properties.

(Fig 4.6: Membrane Curing)

4.6. Testing of Hardened Concrete Specimens:

After the completion of Curing process after the specified time, Concrete
specimens are subjected to few tests called Hardened Concrete Tests. For this project,
we have adopted the tests as:

1) Compression Test
2) Flexure Test

For this project, we have casted 9 Cubes with Nominal Concrete of M25 grade
and 9 Cubes with Polypropylene Fiber Reinforced Concrete of same grade for
compression test.

We have also casted 9 Beams with Nominal Concrete of M25 grade and 9 Beams
with Polypropylene Fiber Reinforced Concrete of same grade for Flexural Strength test.

4.6.1. Compression Test:

31
 Compression test is the most common test conducted on the Hardened concrete
because most of the desirable characteristics properties are qualitatively related to its
compressive strength. The compressive test is carried out on the specimens cubical or
cylindrical in shape. The cube specimen of is size 150x150x150mm. This is conducted
on compression testing machine as shown in fig 4.7.

Test Procedure:

 The specimens are taken out from the curing time.

 The specimens are introduced in the compression testing machine and the machine
will be turned on.
 The force will be applied and increased continuously at a rate equivalent to 20MPa
Compressive stress per minute until the specimen fails.
 Record the maximum force from the testing machine.

Compressive Strength = (Maximum Compressive Force/ Cross Sectional Area )

(Fig 4.7: Compression Testing Machine)

4.6.2. Flexural Test:

32
Flexural strength is one measure of the tensile strength of concrete. It is a measure of an
unreinforced concrete beam to resist failure in bending. It is measured by loading 100*100
mm concrete beams with a span length of 500 mm. This test is performed by three point
loading experiment. The Third point loading test applies the forces at the 1/3 and 2/3 points
equally from the top side by distributing a single centered force through a steel beam to two
points rather than one. The beam is supported at two points from below near the ends. The
bending moment is lower in a third point test than in a centre point test. Highway designer
use a theory based on flexural strength for design of pavements. However, there is very
limited use of flexural testing for structural concrete.

Flexural strength tests are extremely sensitive to specimen preparation, handling, and curing
procedure. Beams are very heavy and can be damaged when handled and transported from
the jobsite to the lab. Allowing a beam to dry will yield lower strengths. The beams must be
cured in a standard manner, and should be tested while wet. Meeting all these requirements
on a job site is extremely difficult and hence often results in unreliable and generally low
MR values. A short period of drying can produce a sharp drop in flexural strength. The
flexural testing machine looks a like fig4.8 shown below.

Test Procedure:

 The specimens are taken out from the curing time.

 The test specimen shall be placed in the machine correctly centered with the
longitudinal axis of the specimen at right angles to the roller.
 For molded specimen the mould filling direction shall be normal to the direction of
loading
 The load shall be applied at a rate of loading of 400kg/min for 150 cm specimens and
at a rate of 180kg/min for 10cm specimen
 Record the maximum force from the testing machine.

Flexural Strength = (Maximum Force* length of beam/width*depth2 )

33
 (Fig 4.8 : Flexure Testing Machine)

The broken/tested fiber reinforced concrete looks like fig4.9 as displayed below.

(Fig 4.9 : Specimen after breaking)

34
 CHAPTER:5

RESULTS AND DISCUSSIONS

5.1. Results and Analysis for Compressive Test of Concrete:

Compressive Strength = Average Load/ Cross Sectional Area

Units:N/mm2

Table: 5.1 Average of 3 cubes of Nominal concrete for 7 days

Average
Cross
Average Compressive
[Link] Days Load(KN) sectional Area
Load (N) Strength
(mm2)
(N/mm2)
1 688
687*103 N 30.533
2 7 686 150*150mm
N/mm2
3 686

From the above table we noticed that the average compressive strength of nominal concrete
of 3 cubes for 7 days is 30.355N/mm2

Table: 5.2 Average of 3 cubes of Nominal concrete for 14 days

Average
Cross
Average Compressive
[Link] Days Load(KN) sectional Area
Load (N) Strength
(mm2)
(N/mm2)
1 798
35.377
2 14 795 796*103 N 150*150mm
N/mm2
3 796

35
From the above table we noticed that the average compressive strength of nominal concrete
of 3 cubes for 14 days is 35.377N/mm2

Table :5.3 Average of 3 cubes of Nominal concrete for 28 days

Average
Cross
Average Compressive
[Link] Days Load(KN) sectional Area
Load (N) Strength
(mm2)
(N/mm2)
1 911
2 28 910 910*103 N 150*150mm 40.45 N/mm2
3 910

From the above table we noticed that the average compressive strength of nominal concrete
of 3 cubes for 28 days is 40.45 N/mm2

Table: 5.4 Average of 3 cubes of Fiber Reinforced concrete for 7 days

Average
Cross
Average Compressive
[Link] Days Load(KN) sectional Area
Load (N) Strength
(mm2)
(N/mm2)
1 660
2 7 674 671*103 N 150*150mm 29.88 N/mm2
3 679

From the above table we noticed that the average compressive strength of fiber reinforced
concrete of 3 cubes for 7 days is 29.88N/mm2

36
Table: 5.5 Average of 3 cubes of Fiber Reinforced concrete for 14 days
Average
Cross
Average Compressive
[Link] Days Load(KN) sectional Area
Load (N) Strength
(mm2)
(N/mm2)
1 747
2 14 750 750*103 N 150*150mm 33.33 N/mm2
3 753

From the above table we noticed that the average compressive strength of fiber reinforced
concrete of 3 cubes for 14 days is 33.33N/mm2

Table: 5.6 Average of 3 cubes of Fiber Reinforced concrete for 28 days

Average
Cross
Average Compressive
[Link] Days Load(KN) sectional Area
Load (N) Strength
(mm2)
(N/mm2)
1 882
2 28 884 884*103 N 150*150mm 39.38 N/mm2
3 884

From the above table we noticed that the average compressive strength of fiber reinforced
concrete of 3 cubes for 28 days is 39.38 N/mm2

37
 Compressive Strengths of Nominal Concrete vs
Fiber Reinforced Concrete
45
40.45
39.28
40
35.377
35 33.33
COMP. STRENGTH (MPA)

30.533 29.82
30

25

20 Nominal Concrete
Fiber Reinforced Concrete
15

10

0
7 14 28
TIME PERIOD IN DAYS

Graph:5.1: Compressive Strengths of Nominal Concrete vs Fiber Reinforced Concrete

Discussions:

 The above graph represents the compressive strength of nominal concrete and fiber
reinforced concrete.
 On “X” axis it represents the days of curing of concrete.
 On “Y” axis it represents the compressive strength of concrete in MPa.
 By adding 5% of fibers to the weight of the cement. It is also observed that there is
no much variation of Compressive Strength in both the concretes. In 7days, 14days
and 28days.
 After 7 days’ nominal concrete recorded a compressive strength of 30.533MPa
whereas after 14 days it got enhanced to 35.377MPa and it was observed to be
40.45MPa after 28 days.
 After 7 days fiber reinforced concrete recorded a compressive strength of
29.82MPa whereas after 14 days it got enhanced to 33.3MPa and it was observed to
be 39.28MPa after 28 days.

38
  It is also observed that there is no much impact in Compressive Strength concrete
by membrane curing.

5.2. Results and Analysis for Flexural Test of Concrete:

Flexural Strength = Average Load*Length/ Width*Depth2

Units: N/mm2

Table: 5.7 Average of 3 Beams of Nominal concrete for 7 days

Average
Average Cross
Length Compressive
[Link] Days Load(KN) Load sectional
(mm) Strength
(N) Area (mm2)
(N/mm2)
1 5
2 7 5 5*103 N 500mm 100*100mm 2.5 N/mm2
3 5.2

From the above table we noticed that the average flexural strength of nominal concrete of 3
beams for 7 days is 2.5 N/mm2

Table:5.8 Average of 3 Beams of Nominal concrete for 14 days

Average
Average Cross
Length Compressive
[Link] Days Load(KN) Load sectional
(mm) Strength
(N) Area (mm2)
(N/mm2)
1 6.4
6.5*103
2 14 6.4 500mm 100*100mm 3.25 N/mm2
N
3 6.7

39
From the above table we noticed that the average flexural strength of nominal concrete of 3
beams for 14 days is 3.25 N/mm2

Table:5.9 Average of 3 Beams of Nominal concrete for 28 days

Average
Average Cross
Length Compressive
[Link] Days Load(KN) Load sectional
(mm) Strength
2
(N) Area (mm )
(N/mm2)
1 7.1
2 28 7 7*103 N 500mm 100*100mm 3.5 N/mm2
3 7.1

From the above table we noticed that the average flexural strength of nominal concrete of 3
beams for 28 days is 3.5 N/mm2

Table: 5.10 Average of 3 Beams of Fiber Reinforced concrete for 7 days

Average
Average Cross
Length Compressive
[Link] Days Load(KN) Load sectional
(mm) Strength
(N) Area (mm2)
(N/mm2)
1 8.2
8.2*103
2 7 7.9 500mm 100*100mm 4.1 N/mm2
N
3 8.5

From the above table we noticed that the average flexural strength of fiber reinforced
concrete of 3 beams for 7 days is 4.1 N/mm2

40
Table:5.11 Average of 3 Beams of Fiber Reinforced concrete for 14 days
Average
Average Cross
Length Compressive
[Link] Days Load(KN) Load sectional
(mm) Strength
(N) Area (mm2)
(N/mm2)
1 11
11.5*103
2 14 11.6 500mm 100*100mm 5.75 N/mm2
N
3 11.8

From the above table we noticed that the average flexural strength of fiber reinforced
concrete of 3 beams for 14 days is 5.75 N/mm2

Table: 5.12Average of 3 Beams of Fiber Reinforced concrete for 28 days

Average
Average Cross
Length Compressive
[Link] Days Load(KN) Load sectional
(mm) Strength
(N) Area (mm2)
(N/mm2)
1 12.9
13.5*103
2 28 13.6 500mm 100*100mm 6.75 N/mm2
N
3 14

From the above table we noticed that the average flexural strength of fiber reinforced
concrete of 3 beams for 28 days is 6.75 N/mm2

41
 Flexural Strengths of Nominal Concrete vs Fiber
Reinforced Concrete
8
FLEXURAL STRENGTH (MPA)

7 6.75

6 5.75

5
4.1
4 3.5
3.25 Nominal Concrete
3 2.5 Fiber Reinforced Concrete

0
7 14 28
TIME PERIOD IN DAYS

Graph:5.2: Flexural Strengths of Nominal Concrete vs Fiber Reinforced Concrete

Discussions:

 The above graph represents the Flexural strength of nominal concrete and fiber
reinforced concrete.
 On “X” axis it represents the days of curing of concrete.
 On “Y” axis it represents the flexural strength of concrete in MPa.
 By adding 5% of fibers to the weight of the cement. It is also observed that there is
an increase in flexural Strength in fiber rein forced concrete compare to nominal
concrete. In 7days, 14days and 28days.
 After 7 days’ nominal concrete recorded a flexural strength of 2.5 MPa whereas
after 14 days it got enhanced to 3.25 MPa and it was observed to be 3.5 MPa after
28 days.
 After 7 days fiber reinforced concrete recorded a flexural strength of 4.1 MPa
whereas after 14 days it got enhanced to 5.75 MPa and it was observed to be 6.75
MPa after 28 days.

42
 We observed that the Flexural variation, there is about 45% more Flexural Strength
than the Nominal Concrete.

43
 CHAPTER: 6

CONCLUSIONS

After the execution of our theoretical ideas, as practical applications, the above stated results
were obtained. Based on the results that we have achieved, here are the Conclusions of our
project:

 Upon the addition of 5% of polypropylene Fibre's, it was observed that there is an

increase of Flexural Strength in the concrete.

 It is also observed that there is no much variation of Compressive Strength in both

the concretes.

 Also, we haven't adopted regular pond curing, but have used membrane Curing.
Eventually, we haven't used a single drop of water for curing.

 Also, observing the Flexural variation, there is about 45% more Flexural Strength
than the Nominal Concrete.

 The amount of Reinforcement could be minimized upon the increase of Flexural

Strength.

44
 REFERENCES

[1] ArnonBentur& Sidney Mindess, ‘‘Fiber reinforced cementitious composites’’ Elsevier

applied science London and Newyork1990.

[2] Dr. N. Ganesan& Dr. [Link], Behaviour of steel fibre reinforced high
performance concrete members under flexure, Behaviour of steel fibre reinforced high
performance concrete members under flexure May 2007, Vol. 88, pp 20-23,2007.

[3] IS:516-1959, Indian standard methods of tests for strength of concrete, Bureau of Indian
Standards, New Delhi,India.

[4] IS:2386 (part-1)-1963, “Methods of testing for aggregate forconcrete”.

[5] IS:4031,“methods of tests conducted on cement” Bureau of Indian standards, NewDelhi.

[6] IS:10262-2009, “Recommended guidelines for concrete mix design, Bureau of Indian
standards”, New Delhi,India.

[7] M.S. Shetty, “Concrete Technology”, [Link]& company Ltd, NewDelhi.

[8] Mukesh Shukla, “Behavior of Reinforced Concrete Beams with Steel Fibres under
Flexural Loading”, International Journal of Earth Sciences and Engineering,Volume 04,
No 06 SPL, October 2011, pp 843-846

[9]NatarajaM.C.,[Link].P,(1998),“Steelfiberreinforcedconcreteundercomp
ression”,TheIndianConcreteJournal,26(3), pp353-356.

[10] Perumalsamy N. Balaguru, Sarendra P. Shah, ‘‘Fiber reinforced cement

composites’’, Mc Graw Hill International Editions1992.

[11] [Link],[Link],”An appraisal of the membrane method of

curing concrete pavements”, engineering experiments station bulletin
108.

[12] ASTM Designation: C 309 – 03 “Standard Specification for Liquid

Membrane-Forming Compounds for CuringConcrete”.

45
[13] [Link],”A Comparative Study on Methods of curing Concrete-
Influence of Humidity”, international journal of engineering research and applications
(IJERA) ISSN: 2248-9622 Vol 3,Issue3,May June 2013 ,pp1161-1165.

46