CHAPTER 3

EXPERIMENTAL METHODOLOGY

3.1. Introduction

This chapter outlines the experimental program, planned for the present investigation. To
achieve the objectives, an experimental program was planned to investigate mechanical and
durability properties of waste foundry sand concrete. The experiments were conducted on the
standard cube (150mm x 150mm x150mm) and standard beam (100mm x 100mm x 500mm)
of concrete mix M30 with different percentage of waste foundry sand i.e. 0%, 10%,
20%,30%,40% and 50% by weight. The experiment was designed to study
1. Compressive strength
2. Split Tensile strength
3. Flexural strength
4. Permeability
5. Ultrasonic pulse velocity
The description of the aforementioned experimental program is put forth in the chapter under
various heads giving insight into the material properties, mix proportions, casting procedure,
curing and the testing of created specimens carried out to achieve the objectives.
3.2. Test programme
The properties of materials used in concrete are determined in laboratory as per relevant code
of practice. Different materials used in the present study were cement, natural coarse
aggregate, waste foundry sand, fine aggregate, and water. The materials in general,
conformed to the specifications laid down in the relevant Indian Standard Codes. The
materials used were having the following characteristics.
3.3 Properties of Concrete Constituents
The determination of the properties of the constituents of concrete is necessary to ensure that
they do not contain any deleterious element which may affect the behavior of the composite
or they may not conform to the specified requirement necessary to achieve a standard of
performance. The sub-sections under this head give the details of the tests carried out and the
specifications as mentioned in the IS codes.
3.3.1. Cement

Although all materials that go into the concrete mix are essential, cement is very often the
most important because it is usually the delicate link in the chain. The function of cement is,
first of all, to bind the sand and stone together and second to fill up the voids in between sand
and stone particles to form a compact mass. Although it constitutes only about 20 per cent of
the volume of concrete mix, it is the active portion of binding medium and is the only
scientifically controlled ingredient of concrete. Any variation in its quantity affects the
compressive strength of the concrete mix. In the present investigation, Ordinary Portland
Cement (OPC) of 43 Grade BANGUR was used for all concrete mixes.various test are
conducted and the results are tabulated in Table 3.1

Table 3.1 Properties of Cement

Characteristics Experimental values Recommended values

Specific Gravity
31.5 26– 33%

Initial setting Time 40(min) 30 min (Minimum)

Final Setting Time
350(min) 600 min (Maximum)

Specific Gravity 3.05 3-3.25

Compressive strength
(MPa)

(i) 3-days 23.8 (MPa) 23 ( MPa)

(ii) 7-days 35.6 (MPa) 33 (MPa)

(iii) 28-day 46.3 (MPa) 43 (MPa)

Soundness, Le
Chatelier’s test 4 mm 10 mm (Maximum)

Loss on Ignition
3.94% 5% (Maximum)

3.3.2. Aggregates

The aggregate is the matrix or principal structure consisting of relatively inert and coarse
particles. The coarse aggregate is used primarily for the purpose of providing bulk to the
concrete. The most important function of fine aggregates is to assist in producing a workable
and a uniform concrete mix. The fine aggregate also assists the cement paste to hold the
coarse aggregate particles in suspension. This action promotes plasticity in the concrete mix
and prevents segregation of the paste and coarse aggregates during its transportation. The
aggregates provide about 75 per cent of the body of concrete and hence their influence is
extremely important. The properties of these particles greatly affect the performance of
concrete.

3.3.3 Fine Aggregate

IS: 383-1970 defines the fine aggregate, as the one passing 4.75mm IS sieve. The fine
aggregate is often termed as a sand size aggregate. Locally available riverbed sand was used
in the present study. Total weight of sample taken =2000 g is taken and the result of sieve
analysis of fine aggregate is listed in Table 3.2 and the particle size distribution is shown in
Fig: 3.1
Table 3.2 Sieve Analysis of Fine Aggregate
Sieve Size Weight Retained Cumulative wt % Cumulative wt
(mm) (gm.) retained retained (gm.)
(gm.)
4.75 18 18 0.9
2.36 43 61 3.05
1.18 267 328 16.4
0.6 540 868 43.4
0.3 982 1850 92.5
0.15 115 1965 97.8
Pan 35 2000 100

Fineness Modulus =Sum of cumulative weight retained /100

Fineness Modulus =354.05/100
=3.54
Hence as per IS 383-1970, fine aggregate lies to Grading Zone II
 100

90
Percent Passing (By Weight)

80

70

60

50

40

30

20

10

0
0.1 1 10
Grain Size (mm)

Fig: 3.1 Particle Size Distribution of Fine Aggregate

Fig: 3.2 Fine aggregate

3.3.4. Coarse Aggregate
The aggregate having size more than 4.75 mm is termed as coarse aggregate. The graded
coarse aggregate is described by its nominal size i.e. 40mm, 20mm, 16mm, 12.5mm etc.
80mm size is the maximum size that could be conveniently used for making concrete. In this
study coarse aggregate is conformed to IS: 383-1970. The result of sieve analysis for 20mm
maximum size of coarse aggregate (MSA) is tabulated in Table 3.3
 Fig: 3.3 Coarse Aggregate

Table 3.3 Sieve Analysis of Coarse Aggregate (20mm MSA)

Sieve Size Weight Retained Weight passing % Weight passing
(mm) (gm.) (gm.) (gm.)
40 0 2000 100
20 245 1755 87.75
16 378 1377 68.85
12.5 943 434 21.7
10 218 216 10.8
4.75 190 26 1.3
2.36 26 0 0

The result of the sieve analysis conforms to IS 383-1970 Table 2 for 20mm size of coarse
aggregate. Hence the above aggregate can be used as nominal size of 20mm coarse
aggregate. The particle size distribution curve has been shown in Fig:3.4
 100

90
Percent Passing(By Weight)

80

70

60

50

40

30

20

10

0
1 10 100
Grain Size (mm)

Fig: 3.4 Particle Size Distribution of Coarse Aggregate (20mm)

Table 3.4: Sieve analysis of coarse aggregate (10 mm MSA)

Cumulative
Weight Cumulative %
IS Sieves weight Percent finer
retained(g) weight retained
retained(g)
12.5mm 32.0 32.0 0.64 99.36
10.0mm 2230.0 2262.0 45.24 54.76
6.3mm 1693.0 3955.0 79.1 20.90
4.75mm 311.0 4266.0 85.32 14.68
2.36mm 571.0 4837.0 96.74 3.26
pan 163.0 5000.0 100 0

The particle size Distribution Curve has been plotted and shown in Fig: 3.5. Based on the
above observation it has been found that the coarse aggregate lies in grading zone I
The properties of fine and coarse aggregate are listed in Table 3.5
Table 3.5 Properties of Aggregate
Property Fine aggregate Coarse aggregate
Fineness modulus 3.54 7.14
Specific gravity 2.61 2.69
Grading Zone II I
3.3.5 Constituent of Waste Foundry Sand

Ferrous and nonferrous metal casting industries produce several million tons of byproduct in
the world. WFS is the major byproduct of metal casting industry and successfully used as a
land filling material for many years. But the use of waste foundry sand for land filling is
becoming a problem due to the rapid increase in disposal cost. In an effort to use the WFS in
large volume, research has been carried out for its possible large-scale utilization in making
concrete as partial replacement of fine aggregate Foundry industry produces a large amount
of by-product material during the casting process. The ferrous metal casts in the foundry are
cast iron and steel, nonferrous metal is aluminum, copper, brass and bronze. Over 70% of the
total by-product material consists of sand because moulds consist usually of molding sand,
which is easily available, inexpensive, resistance to heat damage and easily bonded with the
binder and other organic material in the mould. Foundry industry uses high-quality specific
size silica sand for their molding and casting process. These WFS is black in color and
contains a lot of fines. In the present study waste foundry sand was obtained from Aligarh
and the constituent of waste foundry sand are listed in Table 3.5

Table3.6 Constituent of Waste Foundry Sand

Constituent Value (%)

SiO2 78.6

Al2O3 7.72

FeS2 1.07

MgO 5.25

Kcl 1.79

K2O 0.29

TiO2 0.13
3.3.6 X-ray diffraction and secondary scanning electron microscopy

The results regarding the X-ray diffraction (XRD for phase) of WFS are shown in Figure 3.2
and 3.2 The WFS used in this study revealed a high content of silicon oxide (SiO2) because
the green sand has a high silica content.

Fig 3.5 Secondary Electron Microscope Image of Waste Foundry Sand

 Fig: 3.6 X ray Diffraction images of Waste Foundry Sand

Waste foundry sand was tested for various properties like specific gravity, fineness modulus
moisture content etc. and the result of the test are listed in Table 3.6

Table 3.7 Properties of Waste Foundry Sand

Property Value

Specific gravity 2.53

Moisture content 0.66

Clay lump and friable particle (%) 0.50

Plastic index Non-plastic

Fineness modulus 3.75

Material finer than 75 microns (%) 8.15

3.3.7 Grading of waste foundry sand

In order to determine the grading zone of waste foundry sand. Sieve analysis has been carried
out as per IS 383-1970 and the results of the sieve analysis are tabulated in Table 3.8

Table 3.8 Sieve Analysis of Waste Foundry Sand

Sieve Size Weight Retained Weight Passing % Weight passing

(mm) (gm.) (gm.)
4.75 10 1990 99.5
2.36 86 1904 95.2
1.18 70 1834 91.7
0.6 332 1502 75.1
0.3 1072 430 21.5
0.15 238 160 8
Pan 32 0 1.6

The results of the sieve analysis show that the waste foundry sand lies in zone-II.

WFS F.A
100

90
PERCENT PASSING (BY WEIGHT)

80

70

60

50

40

30

20

10

0
0.1 1 10
GRAIN SIZE (MM)

Fig: 3.7 Comparison of Particle Size Distribution of WFS and Fine Aggregate

3.3.8 Water

Generally, water that is suitable for drinking is satisfactory for use in concrete. Water from
lakes and streams that contain marine life also usually is suitable. When water is obtained
from sources mentioned above, no sampling is necessary. When it is suspected that water
may contain sewage, mine water, or wastes from industrial plants or canneries, it should be
used in concrete unless tests indicate that it is satisfactory. Water from such sources should
be avoided since the quality of the water could change due to low water or by intermittent
discharge of harmful wastes into the stream. The water used was the potable water as
supplied in the structures laboratory of our institute. Water used for mixing and curing should
be clean and free from injurious amounts of oils, acids, alkalis, salts and sugar, organic
materials or other substances that may be deleterious to concrete. As per IS: 456-2000
potable water is generally considered satisfactory for mixing and curing of concrete.
Accordingly, potable water was used for the preparation of all concrete specimens.
3.3.9 Super Plasticizers: A super plasticizer is a material other than water, aggregates and
cement used as an ingredient of concrete and added to the batch immediately before or
during the mixing. Super Plasticizers (IS 9103 – 1999) are used where a high degree of
workability and its retention are required, where a delay in transportation or placing is
required, or when high ambient temperatures cause rapid slump loss. It facilitates production
of high quality concrete. The super plasticizers enable quicker placing and compaction of
concrete. They also minimize the risk of segregation and bleeding.
3.4 Mix Design Procedure
To design a concrete mix for the desired strength, first, we need to decide the constituents of
the concrete mix such as cement, fine aggregate, coarse aggregate, admixtures etc. and their
optimum quantity that will result in achievement of the requisite performance. In general, the
acceptance criteria of a concrete mix are its workability in the fresh state and compressive
strength at the age of 28 days. As per the guidelines of IS-10262: (1982), the normal strength
concrete mix M30 was designed.
Table 3.9: Concrete mix proportion
Water WFS
Mix Cement Fine Coarse
cement (% by
designation (kg/m3) aggregate(kg/m3) aggregate(kg/m3)
ratio weight)
WFS00%
475 652 1063 0.4 0.00

WFS10% 475 652 1063 0.4 10

WFS20% 475 652 1063 0.4 20
WFS30% 475 652 1063 0.4 30
WFS40% 475 652 1063 0.4 40
 WFS50% 475 652 1063 0.4 50

The details of the specimens cast during the entire experimental program are summarized in
the Table 3.10

Table 3.10: Details of specimens

No of
Total no of
Avg. no. of specimens
Type and size of specimens
Type of test specimens used for
specimens for each
tested each % of
replacement
WFS
Compressive
Cubes (150cm x150cm and
3 3 18
150cm) permeability
test

Standard beams
Flexural
(100mm x100mm x 3 3 9
strength test
500mm)

3.5 Mixing, Casting, and Curing

After the preliminary tests on the constituents of concrete confirmed the suitability of
ingredients and the design mix was found to be satisfactory, the task of casting the beams was
taken up. The available laboratory equipment was utilized in the accomplishment of this
experimental program. The guidelines in the IS-10262: (2009) were strictly adhered to in the
process of mixing of concrete. Firstly, the coarse aggregate was washed a day before casting
in order to make it silt-free and was laid to dry. On the following day, the coarse aggregate
was found to be satisfactorily moist. This was necessary to prevent absorption of moisture by
the aggregate from the water being added to the mix i.e. the designed water cement ratio had
to be carefully regulated. Next, the coarse aggregate was mixed with the fine aggregate. The
waste foundry sand was added gradually during mixing in concrete mixes. The process of
mixing was performed by hand mixing The compaction of concrete was performed using a
platform vibrator with speed range of 12000 ± 400 rpm and amplitude range of 0.555mm.
The concrete was filled in three layers in all the moulds. About an hour after casting, the
surface was smoothened with a trowel. The specimens were demoulded 24 hours later and
after labeling was put under water for a period of 7days 28 days 56 days and 91 days for
curing. After the above specified days, the concrete specimens were taken out and dried
sufficiently and were tested at room temperatures. The beams were tested under two-point
loading arrangement and the central deflection was noted.

3.6 Test Programme

Various types of test such as compressive strength, tensile strength, flexural strength and
permeability are conducted on the concrete cube of size 150mm x 150mm x 150mm and
beam of size 100mm x 100mm x 500mm.

3.6.1 Compressive Strength

The compressive strength of concrete is one of the most important and useful properties of
concrete. In most structural applications concrete is employed primarily to resist compressive
stresses. In those cases, where strength in tension or in shear is of primary importance, the
compressive strength is frequently used as a measure of these properties. Therefore, the
concrete making properties of various ingredients of the mix are usually measured in terms of
the compressive strength. Compressive strength is also used as a qualitative measure for other
properties of hardened concrete. The compressive strength of concrete is generally
determined by testing cubes or cylinders made in laboratory or field. In the laboratory, the
compressive strength is determined by compression testing machine. For a given cement and
acceptable aggregates, the strength that may be developed by workable, properly placed
mixture of cement, aggregate and water (under the same mixing, curing and testing
conditions) is influenced by:
(a) Ratio of cement to mixing water;
(b) Ratio of cement to aggregate;
(c) Grading, surface texture, shape, strength, and stiffness of aggregate particles;
(d) The maximum size of aggregate.
In the present study cube of size 150mm x 150mm x 150mm has been used for determination
of compressive strength of concrete. The concrete cube has been placed in compression
testing machine and the load is applied by compression testing machine. The load
corresponding to the failure of the specimen has been recorded and compressive strength was
determined by dividing the load by contact area (22500 mm2)
The compression testing machine is shown in Fig 3.4
Fig: 3.8 Compression Testing Machine

Fig: 3.9Tested Specimen

The compressive strength of the hardened concrete cubes of size 150mm x 150mm x 150mm
was found using the compression testing machine of capacity 200kN. The tests rate of 14N/
mm2/ min after the specimen had been centered in the testing machine.
3.6.2 Tensile Strength

The tensile strength of concrete is approximately 10% of its compressive strength. Tensile
splitting strength tests of concrete block specimens were determined as per IS: 5816-
1999.After curing of 28 days the specimens were tested for tensile strength using a calibrated
compression testing machine of 1000 KN capacity.
3.6.3 Flexural Strength

Flexural strength is one measure of the tensile strength of concrete. It is a measure of a

concrete beam or slab to resist failure in bending. It is measured by loading 100 x 100 x
500mm concrete beams. The flexural strength is expressed as Modulus of Rupture in MPa
and is determined by standard test methods IS: 516-1959 (third-point loading) Flexural
Strength of is about 10 to 20 percent of compressive strength depending on the type, size and
volume of coarse aggregate used. However, the best correlation for specific materials is
obtained by laboratory tests for given materials and mix design. The Modulus of Rapture
determined by third-point loading is lower than the modulus of rapture determined by center-
point loading

The Flexural Strength or modulus of rupture (fb) is given by

Fb = Pl / bd2 (when a > 20.0cm for 15.0cm specimen or > 13.0cm for 10cm specimen)
Or
Fb = 3pa/bd2 (when a < 20.0cm but > 17.0 for 15.0cm specimen or < 13.3 cm but > 11.0cm
for 10.0cm specimen.)
Where,
a = the distance between the line of fracture and the nearer support, measured on the center
line of the tensile side of the specimen
b = width of specimen (cm)
d = failure point depth (cm)
l = supported length (cm)
p = max. Load (kg)
Fig: 3.10 Flexural Strength Determination

Fig: 3.11 Tested Specimen

3.6.4 Permeability of Concrete
Permeability is defined as the property that governs the rate of flow of a fluid into a porous
solid. Permeability is also can be defined the ability to resist weathering action, chemical
attack, abrasion, or any process of deterioration. The permeability occurs in hardened
concrete in two scenarios; firstly, from the trapped air pockets from incomplete compaction
and secondly from the empty space due to loss of mixing water by evaporation.

Factor affecting Permeability

 W/C ratio:
The mixing water is indirectly responsible for permeability of the hydrated cement paste
because its content determines first the total space and subsequently the unfilled space after
the water is consumed by either cement hydration reactions or evaporation to the
environment. Concrete will not be vulnerable to water-related destructive phenomena if there
is a little or no evaporable water left after drying and provided that the subsequent exposure
of the concrete to the environment did not cause to re-saturation of the pores. The latter, to a
large extent, depends on the hydraulic conductivity, which is also known as the coefficient of
permeability (K).
 The use of Admixtures:
Such as silica fume, latex emulsions, and high range water reducers allows placement of
highly impermeable concrete. More information on the effects of these admixtures, concrete
mix design, and curing is needed so that low permeability concretes can be uniformly
specified and manufacture.
Determination of Permeability
Permeability tests were conducted in accordance with IS 3085-1965 and the coefficient of
permeability was calculated using the following equation given in the code.
K= Q / At [H/L]
Where
K= coefficient of permeability (cm/s)
Q= volume of water collected (ml)
T= time (second)
H= pressure head (cm)
Fig: 3.12Water permeability testing apparatus

Fig: 3.13 Sealed specimen

The apparatus consists of a reservoir which is the 100mm diameter and about 500mm long.
The permeability cell has a diameter of 115mm and the height of the cell is 115mm. The
reservoir is fitted with a scale. Necessary valves are attached to the cell for admitting water,
compressed air and for draining water. Air permeability cell assembly for maintaining a
pressure in the range of 5 kg/cm2 supply of clean water was made the available pressure of 5
kg/cm2 has been used. The specimen was thoroughly cleaned with a stiff wire brush to
removal all laitance. The test consists of subjecting the concrete specimen of known
dimension in a specially designated cell, to a known hydrostatic pressure from one side and
measuring the quantity of water percolating through it in a given interval of time through the
other end of the specimen. The quantity of water that is collected is proportional to
permeability.

3.6.5 Ultra sonic pulse velocity Test (UPV)

Ultrasonic test on concrete is a non-destructive test to assess the homogeneity and integrity
of concrete This test essentially consists of measuring travel time, T of ultrasonic pulse of 50
to 54 kHz, produced by a transducer, held in contact with one surface of the concrete member
under test and receiving the same by a similar transducer in contact with the surface at the
other end. With the path length Land time of travel T, the pulse velocity (V=L/T) is
calculated Higher the elastic modulus, density, and integrity of the concrete, higher is the
pulse velocity. The ultrasonic pulse velocity depends on the density and elastic properties of
the material being tested

The pulse velocity in concrete may be influenced by:

a) Path length
b) Lateral dimension of the specimen tested
c) Presence of reinforcement steel
d) Moisture content of the concrete
The influence of path length will be negligible provided it is not less than 100mm when
20mm size aggregate is used or less than 150mm for 40mm size aggregate. Pulse velocity
will not be influenced by the shape of the specimen, provided its least lateral dimension is not
less than the wavelength of the pulse vibrations. The velocity of pulses in steel bar is
generally higher than they are in concrete. For this reason, pulse velocity measurements made
in the vicinity of reinforcing steel may be high and not representative of the concrete. The
influence of the reinforcement is generally small if the bars runs in a direction at right angles
to the pulse path and the quantity of steel is small in relation to the path length. The moisture
content of the concrete can have a small but significant influence on the pulse velocity. In
general, the velocity is increased with increased moisture content, the influence is more
marked for lower quality concrete.

Fig: 3.8 Ultrasonic pulse velocity test

3.7 Concluding Remarks

This chapter reports the detailed procedure of the process of casting, curing and testing of
concrete specimens. The results that were obtained from the experimental investigations on
normal strength concrete of characteristic strength 30MPa and have been discussed in detail.
The results have been analyzed meticulously and discussed in the subsequent chapters.