393

APPENDIX - A
Mix Design of M20 grade Concrete Using Ordinary Portland Cement as
per 10262 1982.
a) Design Stipulations:
i). Characteristic compressive strength required in the field at 28
days = 20 MPa.
ii). Maximum size of aggregate (angular) = 20 mm.
iii). Degree of workability (compacting factor) = 0.90.
iv). Degree of qualify control = Good
v). Type of exposure = mild.
b) Test data for materials :
i). Specific gravity of Cement = 3.10
ii). Specific gravity of Metakaolin = 2.50
iii). Compressive strength of cement at 7 days (satisfies the
requirements of IS: 12269 1987) = 43 MPa.
iv). Specify gravity of coarse aggregate = 2.56
v). Specify gravity of fine aggregate = 2.50
vi). Water absorption of coarse aggregate = 0.25%.
vii). Fine aggregate belongs to zone II and satisfies the
requirements of table 4, IS: 383 1970.
viii). Coarse aggregate satisfies the requirement of table 2, IS: 383
1970.


394



Steps involved in Mix Design:
Step 1: The target mean strength for characteristic cube
compressive strength of 20 MPa is :
Ft = CK + K * S.
= 20 + 1.65 x 4.0 = 26.60 MPa
Where K = 1.65, a statistical constant (assuming that accepted
proportion of low results to be 1 in 20).
And S = standard deviation (from table 8, page 23 of IS: 456 2000)
= 4.0
Step 2: The water to cement ratio for the target mean strength of
26.60 MPa (from fig :2 of IS: 10262 1982) = 0.54
Minimum cement content = 300 + 0 = 300 kg/m
3
( from table 5 of IS:
456 2000, for mild exposure and reinforced concrete mix).
Maximum free water to cement ratio = 0.55 based on several trial
mixes, the free water cement ratio used is = 0.55.
Step 3: From table 4 of IS: 10262 1982, for concrete grade up to
M35 for crushed angular coarse aggregate of 0.6 and fine aggregate of
0.40 and nominal maximum size of aggregate as 20mm.
a) The approximate sand as percentage of total aggregate by
absolute volume = 35%.
b) Water content for cubic meter of concrete (SSD condition) = 186
kg/m
3

The state of the art report on fibre reinforced concrete by ACI
committee gives the percentage of fine to coarse aggregate in a typical
395


mix of SFRC to be between 50 to 100%. In the present study it was
kept at 100%.
For the present mix design of M20 grade concrete, the properties are
Sand confirms to Zone II.
Compacting factor = 0.9.
Water to cement ratio = 0.53.
Coarse aggregate is angular in shape.
The following is the table of adjustments in the values of water
content and sand percentage for the change in conditions stipulated
in table 6 of 10262 1982.
Change in conditions Adjustment required in
Water
content
Percent Sand in total
aggregate
(a) Increase in the
value of compaction
factor by 0.1
+ 3.0 0
(b) Decrease in free
water cement ratio by
0.05
0 -1
Total + 3.0 -1


Step 4: Revised water content = 1.03 x 186
= 191.58 liters / m
3
.
Water / cement ratio = 0.54.
Cement, C = _W_ = 191.58 = 361.47 kg/m
3
.
0.54 0.54
But as per IS: 456-2000, the above quantity of cement is adequate for
mild exposure condition according to Appendix A of IS: 456 1978.
396


Based on several trial mixes the free water cement ratio used is w/c =
0.55.
Cement, Content C = 191.58
0.55
= 348.32 Kg.
= 348 Kg
Step 5: Calculation of quantities of fine aggregate and coarse
aggregate:
Volume of entrapped air for 20 mm aggregate = 2 %
As per clause of 3.5.1 of IS: 10262 1982, we have
V = { W+(C/Sc) + (1/p) (a / sfa) } x (1/1000) and
0.98 = 191.58 + (348/3.10) + _a _ x _ 1_ x _ 1_
0.35 2.50 1000

0.98 x 1000 = 191.58 + 112.26 + _a _
0.875
_a _ = 676.16
0.875
a = 591.64 kg/m
3
.
V = [W + (C/Sc) + (1/1-P) x Ca/Sca] x 1/1000
980 = 191.58 + 348 + 1 x Ca
3.10 0.65 2.56

Ca = 1125 kg/m
3
.
1.664
Where V = absolute volume of fresh concrete
W = Mass of water (kg) per m
3
of concrete.
C = Mass of cement (kg) per m
3
of concrete.
Sc = Specific gravity of cement.
P = ratio of fine to total aggregate by absolute volume.
397


a, Ca = Total masses of fine and coarse aggregate (kg) per m
3
of
concrete respectively and
Sfa, Sca = Specific gravities of saturated surface dry fine
aggregate and coarse aggregate respectively.
The materials obtained per m
3
of M20 grade concrete are
Cement = 348 kg.
Water = 191.58 liters/ m
3

Fine aggregate = 591.64 kg/m
3
.
Coarse aggregate = 1125 kg/m
3
.

The proportions of the materials are:
Water : cement : fine aggregate : Coarse aggregate
= 191.58 : 348 : 591.64 : 1125 : = 0.55 : 1 : 1.70 : 3.23.
The compressive strength of OPC concrete after the trial mixes
is 30.69 MPa at 28 days.
DESIGN OF M50 GRADE CONCRETE
BY
ERNTROY AND SHACKLOCKS METHOD
Specified 28 day cube strength = 50 MPa.
Very good degree of control;
Control factor = 0.80.
Degree of workability - very low.
Type of cement - ordinary Portland cement
Type of coarse aggregate-crushed granite (angular) maximum size -
20mm.
398


Type of fine aggregate - natural sand
Specific gravity of cement = 3.10
Specific gravity of Sand = 2.50
Specific gravity of Coarse aggregate = 2.56
The fine and coarse aggregates contain 5 and 1 percent
moisture respectively and by assumes aggregate is 100 % passing
through 20mm IS sieve and 96% through 10 mm IS sieve.
Average strength =__50__ = 63 MPa.
0.80

Reference number = 18.
With reference to above reference number, the water / cement ratio is
= 0.33.
For 20mm maximum size aggregate and very low workability
aggregate / cement ratio for the desired workability = 2.9
The aggregates are combined so that 30 percent of the material
passes through the 4.75 mm I.S. sieve.
Ratio of fine to total aggregate = 25%.
Required proportions by weight of dry materials are:
Cement : F.A. : C.A. : Water.
1 : ( _25_ x 2.9 ) : ( _75_ x 2.9 ) : 0.33.
100 100

1 : 0.725 : 2.175 : 0.33.
If C = weight of cement required per m
3
of concrete.

Then __C__ + __0.725 C_ + __2.175 C_ + __0.33 C_ = 1000
3.10 2.50 2.56 1
399



C [ 0.32 + 0.29 + 0.849 + 0.33 ] = 1000
C = 558.97 kg/m
3
of concrete.
= 559 kg /m
3
.

Design mix proportion:
Ratio of mix proportion by weight:
Mix Grade Cement Fine
Aggregate
Coarse
Aggregate
W/C.
M50 1 0.725 2.175 0.33
Material requirement (M50)
Mix design ratio 1: 0.725 : 2.175: 0.33
S.No Material required Quantity in kg/m
3

1 Cement 559
2 Fine Aggregate 405
3 Coarse Aggregate 1216
4 Water 184.50 liters
The compressive strength of OPC concrete after the trial mixes is
61.40 MPa at 28 days.







400


APPENDIX - B
CALCULATION OF FIBRE FACTOR F, FOR 1.5% FIBRE CONTENT
Volume fraction of fibres = 1.5%
Volume of steel fibres for 1 m
3
of concrete = 1/100x1.5
= 0.015 m
3

Weight of fibres used for 1 m
3
of concrete = 0.015 x 7850
= 117.75 kg/m
3

Fibre factor F = Vf X (AR) X Bond factor = 1.5/100 x 80 x 0.75
= 0.90















401


APPENDIX C
Curve Fitting:
Linear regression equations are proposed using MS excel work
sheet based on the method of least squares to quantify the effect of
fibre addition on the compressive strength, splitting tensile strength,
modulus of rupture, modulus of elasticity, impact resistance and
abrasion resistance of SFRC and SFRC-MK
The graphical method and the method of least squares are the
useful methods for fitting a curve or a straight line. The method of
least square is mostly used.
R (Xr, Yr)

er
S (Xr, a+bxr)
Y= ax+b Yr
a + bxr

Xr



Fig: A. Scatter diagram
The method of least squares was suggested early in the 19
th

century by the French mathematician Adrien Legendre. The method
of least square assumes that the best fitting line in the curve is the
one for which the sum of the squared of the vertical distance of the
402


point (Xr,Yr) from the line is minimum. This method is more accurate
than the graphical method.
Let y = a + bx (1)
be the equation of the line and R (Xr, Yr) be one of the points of the
data (scatter diagram) from which straight line is to be fitted.
The ordinate of any point Sr on the line vertically above or below
a given point Rr can be found by substituting the abscissa Xr in the
equation (1). The two coordinates of Sr will be (Xr, a + bxr) as shown
in fig 1 above.
The vertical distance er from the line to any point Rr with
coordinates (Xr,Yr) will be given by the equation.
er = Yr (a + bxr) (2)
er represents the difference between the actual ordinate Yr of a
point R in the data and its theoretical ordinate (a + bxr)
Let S = (er)
2
= [ yr (a + bxr)]
2
(3)

r = 1 r = 1
The best fitting line is that line for which sum of the squares q =
(er)
2
is a minimum. We find the values of a and b which make S
minimum as follows:
Differentiating S partially with respect to a and b, equating the
equations so obtained to zero, we get
n
S =

(-2) [yr (a + bxr)] = 0
a
r = 1

and
403


n
S =

(-2)xr [yr (a + bxr)] = 0
b
r = 1
Which yields the system of normal equations

n n
yr = an +b xr (4)
r = 1 r = 1
and
n n n
xr yr = a xr + b (xr)
2
(5)
r = 1 r = 1 r = 1

Solving this system of equations we get,
n n n n
(xr)
2
yr - xr xr yr
1 1 1 1
a = (6)
n n
n (xr)
2
-

[ xr]
2


1 1


n n n
n[ xr yr] - xr (xr)
2

1 1 1
b = (7)
n n
n (xr)
2
-

[ xr]
2


1 1

Where n is the number of points (xr ,yr) of the data
(xr xm)
Substituting tr = h (8)

Where h = the interval between successive values of x assumed to be
equally spaced.
Shifting the origin to the mean xm and compressing the interval to
unity we get the transformed equation (1) referred to the new (t, y)
axes as y = a1 + b1 t (9)
404


Where a1 and b1 are the parameters in the new equation. In
terms of the new co-ordinates, formulae (6) and (7) become

n n n n
(tr)
2
yr - tr tr yr
1 1 1 1
a = (10)
n n
n (tr)
2
-

[ tr]
2


1 1


n n n
n[ tr yr] - tr yr
1 1 1
b = (11)
n n
n (tr)
2
-

[ tr]
2

1 1




n
Since tr = 0
1
The formulae (10) and (11) reduce to


n n
(tr)
2
yr
1 1
a1 =

n
(tr)
2

1





405


n
tr yr
1
b1=
n
n (tr)
2


1


Which further simply to the form

n
a1 = 1 yr (12)

n
1

n
tr yr
1
b1= (13)
n
n (tr)
2


1
After finding the values of a1 and b1 they are substituted in
equation (9) to get the equation for the regression line.










406


APPENDIX -D
List of publications:
S. No Title of Paper
Name of the
Journal/ Conference
Date of
Publication
1
An Experimental
Investigation on
Metakaolin Blended
Concrete in Torsion
using Lime Stone as
Coarse Aggregate.
International
Conference on
Advances in
Concrete &
Construction
(ICACC-2008) by of
Engg.,
7
th
to 9
th
Feb
2008
2
Basic Strength
Properties of
Metakaolin Blended
Concrete using Lime
Stone as Coarse
Aggregate.
National Seminar on
Focusing on
Advances in Civil
Engg.(FACE-08) by of
Engg, Kerala.
21
st
to 23
rd
Feb
2008
3
Durability Studies on
Metakaolin Blended
Concrete
National Level
Seminar on
ENGINEERED
CONCRETES by ICI
at BMS Engg.
College Bangalore.
28
th
to30
th
Mar
2008
4
Basic Strength
Properties of
Metakaolin Blended
High Strength
Concrete using
Crimped G.I Fibres.
One Day National
Seminar on Recent
Advances in
Structural Engg.
(RASE-08) by
J.N.T.U, Anantapur
14
th
April 2008
407


5
Effect of incorporating
Metakaolin & Crimped
Steel Fibres on the
Properties of Fresh &
Hardened Concrete.
International
Symposium
Organised by RILEM
International at IIT
Chennai
17
th
to 19
th
Sep
2008
6
Post cracking
behaviour of
Metakaolin blended
High Strength
Concrete using
crimped steel fibres in
flexure
International
conference organized
by ICI, at New Delhi,
INNOVATIVE
WORLD OF
CONCRETE
11
th
to14
th

December, 2008
7
Basic Strength
properties of
Metakaolin blended
High Strength
Concrete using M.S.
fibres.
National Conference
organized by Bhilai
Institute of
Technology, Durg,
BITCON 2008
7th to 8th
November 2008
8
Durability Studies on
Metakaolin Blended
Concrete
Got Published in the
journal for Research
and Engineering.
( International
Journal)
October 2008
9
Cracking Behaviour of
Metakaolin blended
high strength concrete
by using crimped steel
fibres.
Got published in the
International
Journal for Civil
Engineering.
June 2009
10
Behaviour of
Metakaolin blended
concrete in flexure by
using crimped steel
fibres.
Got published in the
International journal
of Earth sciences
and Engineering
January 2010
11
Behaviour of steel
fibre reinforced High
strength Metakaolin
concrete when
exposed to elevated
temperatures
Got acceptance of
abstract for the
forthcoming
International
conference organized
by ICI in association
with IIT Madras
December 2010


408



View of testing of properities of fine aggregate and cement

Plate No. 3.1 View of superplasticizer(Conplast SP 430)
409





Plate No. 3.2 View of crimped steel fibres

410



Plate No. 3.3 View of Metakaolin


Plate No. 3.4 View of PAN mixer

411





Plate No. 3.5 View of addition of crimped steel fibres in the mixer
412



Plate No. 3.6 View of mixing of Metakaolin and cement

Plate No. 3.7 View of SFRC mix in the fresh state
413






Plate No . 3.8 View of casting of cylinders
414



Plate No. 3.9 View of slump test of the mix


Plate No. 3.10 View of casted cylinders

415



Plate No. 3.11 View of casting of prisms


Plate No. 3.12 View of casted prisms
416



Plate No. 3.13 View of specimens under curing


Plate No 3.14 View of testing of cube in compression
417



Plate No. 3.15 View of testing of cylinder (split tensile test setup)

Plate No. 3.16 View of casted prisms
418



Plate No. 3.18 View of Prisms for impact testing

Plate No. 3.19 View of impact test setup
419



Plate No. 3.20 View of specimen(plain concrete) at failure due to
impact

Plate No. 3.21 View of specimen (SFRC) at failure due to impact
420






Plate No . 3.22 View of cubes after Normal curing
421




Plate No. 3.23 View of specimens after immersion in 5% HCL

Plate No. 3.24 View of specimens after immersion in 5% H2SO4
422



Plate No. 3.25 View of specimens in electric oven for exposure of
thermal cycles

Plate No. 3.26 View of specimens in electric furnace for exposure
to elevated temperatures
423



Plate No. 3.27 View of specimens after exposure to 200
0
C


Plate No. 3.28 View of specimens after exposure to 400
0
C
424



Plate No. 3.28.a View of specimens after exposure to 600
0
C

Plate No. 3.29 View of beam under flexure test
425



Plate No. 3.30 View of beam after flexure test

Plate No. 3.31 View of cracks pattern in beams after failure in
flexure
426




Plate No. 3.32 View of cracks pattern in beams after failure in
flexure






427




Plate No. 3.33 view of testing of slab in flexure
428





Plate No. 3.34 view of observing the central deflections under
loading

429




Plate No. 3.35 view of highlighting the crack pattern on slabs
after testing
430




Plate No. 3.36 view of crack pattern of Reinforced concrete slab
(M20)
431



Plate No. 3.37 view of crack pattern of SFRC slab (M20)
432



Plate No. 3.38 view of crack pattern of SFRC-MK slab (M20)
433



Plate No. 3.39 view of crack pattern of MKC slab (M50)
434



Plate No. 3.40 view of crack pattern of SFRC-MK slab (M50)

435



Plate No. 3.41 view of crack pattern of SFRC slab (M50)

436









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