STUDY ON PROPERTIES OF CONCRETE WITH MANUFACTURED SAND AS REPLACEMENT TO NATURAL SAND

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International Journal of Civil Engineering and Technology (IJCIET)

Volume 6, Issue 8, Aug 2015, pp. 29-42, Article ID: IJCIET_06_08_004

Available online at

http://www.iaeme.com/IJCIET/issues.asp?JTypeIJCIET&VType=6&IType=8

ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication

___________________________________________________________________________

STUDY ON PROPERTIES OF CONCRETE

WITH MANUFACTURED SAND AS

REPLACEMENT TO NATURAL SAND

Yajurved Reddy M

Post-graduate Student, (BE+ME) Dept. of Civil Engineering,

Andhra University, Visakhapatnam, INDIA

D.V. Swetha

Post-graduate Student, (BE+ME) Dept. of Civil Engineering,


S. K. Yajdani

Assistant Professor, Dept. of Civil Engineering,


ABSTRACT

In the present investigation workability, strength and durability of

concrete with manufactured sand as replacement to natural sand in

proportions of 0%, 20%, 40%, 60% and 100% is studied. The experiments

were conducted on M20 and M30 concrete grade with 450 specimens. Slump

cone, compaction factor and vee-bee time tests were conducted to determine

workability. Results showed that as replacement of natural sand by

manufactured sand is increased, there is a decrease in the workability.

Compressive strength, split tensile strength and flexural strength tests were

conducted to determine strength of concrete. The 60% replacement showed an

increase in strength of about 20% and other replacements to an order of

minimum 0.93% in both the grades. The durability study is conducted by

treating specimens for 30 days with 5% concentrated Hydro Chloric Acid and

the concrete mix with 60% replacement has given good durable properties.

Key words: Manufactured Sand, Natural Sand, Durability.

Cite this Article: Yajurved Reddy M, D.V. Swetha and S. K. Yajdani. Study

on Properties of Concrete with Manufactured Sand as Replacement to Natural

Sand. International Journal of Civil Engineering and Technology, 6(8), 2015,

pp 29-42.

http://www.iaeme.com/IJCIET/issues.asp?JTypeIJCIET&VType=6&IType=8

Yajurved Reddy M, D.V. Swetha and S. K. Yajdani


1. INTRODUCTION

Concrete is made with natural sand as fine aggregate. Scarcity of natural sand due to

depletion of natural resources and restrictions due to environmental considerations

made concrete manufacturers to look for suitable alternative fine aggregate. One such

alternative is “Manufactured Sand”. Manufactured sand is the quarry dust or the

crushed granite stone that is sieved and made to suite particle size of natural sand so

as to be used as fine aggregate. It is also called as M-sand.

There is an increase in the use of manufactured sand in the field of concrete

construction due to the lack and scarcity of natural sand. So there is a need to

determine the workability, strength and durability properties of concrete using

manufactured sand as fine aggregate. The study on the strength characteristics of

concrete made with high fine material a comparison between natural and crushed

sands is studied by B.P Hudson. Ilangovanaet al studied the feasibility of the usage of

Manufactured sand as hundred percent substitute for natural sand in concrete.

Nagabhushana and Sharadabai studied the properties of mortar and concrete in which

crushed rock powder (CRP) is used as a partial and full replacement for natural sand.

Rajendra Prasad D.S. et al his research was conducted to study the effect of crushed

rock powder (CRP) as fine aggregate and partial replacement of cement with

admixtures subjected to different water, carbon dioxide and air curing periods. Raman

et al in his paper reports the experimental study undertaken to investigate the

influence of partial replacement of sand with quarry dust, and cement with fly ash on

the concrete compressive strength development. Saeed Ahmad investigated the effects

of crushed and natural sand on the properties of fresh and hardened concrete. The

hardened and durable properties of concrete using quarry dust were investigated by

SivaKumar and prakash. Veerareddy has made an attempt to assess the suitability of

stone dust and ceramic scrap in concrete making. Venumalagavelli has investigated

the effect of partial replacement of cement with Ground Granulated Blast furnace Slag

and sand with Robos and (crusher dust).

Durability of concrete is an important aspect when we are using a new material in

concrete production. When hydrochloric acid and hydrated cement phases react, the

chemicals formed are some soluble and insoluble salts. Soluble salts, mostly with

calcium, are subsequently leached out, whereas insoluble salts along with amorphous

hydrogels, remain in the corroded layer of concrete. Besides dissolution, the

interaction between hydrogels may also result in the formation of compounds like

silicates of iron, aluminum and calcium (Fe-Si, Al-Si, Ca-Al-Si) complexes which

appear to be stable in pH range above 3.5.

Ca(OH)2 + 2HCl CaCl2 + 2H2O

The reaction essentially causes leaching of Ca (OH)2 from the set cement. After

leaching out of Ca (OH)2, C-S-H and ettringite start to decompose, with release of

Ca2+

to counteract the loss in Ca(OH)2 and the set cement starts to disintegrate

accelerating the dissolution.

Ca6Al2(SO4)3(OH)12.26H2O 3Ca2+

+2[Al(OH)4]- +4OH

- +26H2O

3Ca2+

+2[Al(OH)4]- +4OH

- +12HCL 3CaCl2 + 2ALCL3 + 12H2O

There are few indications through experiments about the formation of Friedel’s

salt, C3A.CaCl2.10H2O, by the action of CaCl2, formed due to reaction of HCL with

CH and C3A. Hydrochloric acid attack is a typical acidic corrosion which can be

characterized by the formation of layer structure.

Study On Properties of Concrete with Manufactured Sand as Replacement To Natural Sand


2. RESEARCH SIGNIFICANCE

The objectives of the present investigation are to conduct feasibility study on

concrete made with manufactured sand as fine aggregate. To evaluate the work

ability characteristics in terms of slump, compaction factor and vee-bee time with

addition of manufactured sand as replacement to natural sand (0-100%). To

evaluate the percentage of admixture that should be added to get the required slump

of 40mm-80mm. To evaluate the compressive strength, split tensile strength, Flexural

strength at 3, 7 and28daysby replacing natural sand in proportions of 0%, 20%, 40%,

60% and 100%. To evaluate the compressive strength, split tensile strength, Flexural

strength of concrete when treated with hydrochloric acid.

3. MATERIALS

Ordinary portland cement of 43 gradeis used confirming to IS: 8112-1989. Crushed

granite metal (graded) with 20 mm to a proportion of 60% and 10 mm to a proportion

of 40% is used as coarse aggregate which is tested according to IS: 2386-1963 Part 1

to VIII. River sand according to IS: 383-1970confirming to zone – II is used as fine

aggregate. Manufactured sand confirming to Zone – II as per IS: 383-1970 is used.

Hydrochloric acid of 5% concentration and Ph-2 is used to treat concrete specimens.

Potable fresh water free from concentration of acid or organic substances is used.

Fosrocconplast SP 430 is used as admixture.

Table 1 Properties of Cement

S.No Property Value

1 Specific Gravity 3.12

2 Fineness of Cement by sieving 4%

3 Normal Consistency 32%

4 Initial Setting time

Final setting time

95 minutes

234 minutes

5

3 days compressive strength



25.3 N/mm2

36.6 N/mm2

52.6 N/mm2

Table 2 Properties of Coarse Aggregate

S.No Property Values


2 Density 1691 kg/m3

3 Water Absorption 0.90 %

4 Flakiness Index 14.13 %

5 Elongation Index 21.29 %

6 Crushing value 21.33 %

7 Impact Value 15.40 %

8 Fineness Modulus 6.65



Table 3 Properties of Fine aggregate (River sand)

S.No Property Value

1 Grading of Sand Zone II as per IS 383


3 Density 1671 kg/m3

4 Water absorption 1.51 %


6 Fines 1 %

Table-4 Properties of Fine aggregate (Manufactured sand)

S.No Property Value

1 Grading of Sand Zone II as per IS 383


3 Density compacted 1791 Kg/m3

4 Water absorption 2.26%


6 Fines 6%

All the materials used were locally available in and around Visakhapatnam, India.

Manufactured sand is transported in wet condition to avoid grading. Table-1 shows

the properties of cement which are within the allowable limits. From Table-2, it can

be stated that the properties of coarse aggregate satisfy the standards. Table-3 and

Table-4 gives the properties of natural river sand and manufactured sand.From these

results we can infer that the natural sand and manufactured sand confirms to same

zone but having different fineness modulus, high for manufactured sand and may

yield more strength. The water absorption of manufactured sand is high due to more

fine particles and may lead to low workable mix. The manufactured sand is angular in

shape and natural sand is rounded.

4. MIX DESIGN

The mix design is done according to IS: 10262-2009. The proportions adopted for M20

grade is 1:1.85:4.02 with a w/c of 0.5 and cement content of 330kgs. The proportions

adopted for M30 grade is 1:1.51:3.06 with a w/c of 0.45 and cement content of 402kgs.

A total of five mixes for each grade is adopted i.e., M20 with 0% M-sand, M20 with

20% M-sand, M20 with 40% M-sand, M20 with 60% M-sand, M20 with 100% M-sand,

for M30 grade M30 with 0% M-sand, M30 with 20% M-sand, M30 with 40% M-sand,

M30 with 60% M-sand, M30 with 100% M-sand were used.

5. EXPERIMENTAL INVESTIGATION

The workability of green concrete is determined by slump cone, compaction factor

and vee-bee time tests, as these tests are suitable for low workable mixes also. While

casting the specimens only the workability is measured, if any mix does not have

required slump of 40-80mm then the mix would be made again with plasticizer. The

tests were conducted on both M20 and M30 grade concrete. In accordance with

workability the percentage of admixture required for low workable mixes to make

their slump reach 40-80mm is also determined. Table 5 and 6 determines the

workability properties of different proportions of natural sand replaced by

manufactures sand.



Table 5 Workability Characteristics of M20 Grade Concrete

Mix Slump

(mm)

Compaction

Factor

Vee-Bee

Time(Sec)

Percentage of Admixture

Required For Slump (40-

80mm)

(By the weight of cement)

M20 with 0% M-Sand 50 0.91 9.2 0

M20 with 20% M-Sand 37 0.89 13.1 0.1

M20 with 40% M-Sand 20 0.87 19.9 0.2

M20 with 60% M-Sand 8 0.84 27.5 0.3

M20 with 100% M-Sand 0 0.81 36.1 0.5

Table 6 Workability Characteristics of M30 Grade Concrete

Mix Slump

(mm)

Compaction

Factor

Vee-Bee

Time(Sec)

Percentage of Admixture

Required For Slump (40-

80mm)

(By the weight of cement)

M30 with 0% M-Sand 46 0.89 10.7 0

M30 with 20% M-Sand 27 0.86 16.3 0.1

M30 with 40% M-Sand 19 0.85 20.7 0.2

M30 with 60% M-Sand 7 0.83 29.2 0.3

M30 with 100% M-Sand 0 0.8 39 0.5

Compressive strength, split tensile strength and flexural strength of M20 and M30

grade concrete is determined by conducting the tests on cubes of size 150X150X150

mm, cylinders of 100mm diameter and 300mm length, prisms of 100X100X500 mm.

The tests were conducted according to IS: 516- 1959 .The results were tabulated in

tables 7 and 8.

Table 7 Strength Characteristics of M20 Grade Concrete With different proportions of

manufactured sand

Test at

Day

M20 with

0% M-Sand

M20 with

20% M-

Sand

M20 with

40% M-

Sand

M20 with

60% M-

Sand

M20 with

100% M-

Sand

Compressive Strength (N/mm2)

3 23.03 23.74 24.78 25.77 25.17

7 30.14 31.67 34.51 35.4 34.51

28 40 42.92 44.07 48 45.77

Split Tensile Strength (N/mm2)

3 1.75 1.91 2.05 2.16 2.07

7 2.21 2.33 2.41 2.73 2.66

28 2.93 3.11 3.14 3.67 3.48

Flexural Strength (N/mm2)

3 3.86 3.97 4.16 4.73 4.49

7 4.74 4.87 4.91 5.52 5.04

28 5.78 5.95 6.14 6.82 6.41



Table 8 Strength Characteristics of M30 Grade Concrete With different proportions of

manufactured sand

Test at

Day

M20 with

0% M-Sand

M20 with

20% M-

Sand

M20 with

40% M-

Sand

M20 with

60% M-

Sand

M20 with

100% M-

Sand


3 26.81 27.11 28.29 32.77 31.85

7 35.51 37.62 39.62 45.55 42.07

28 48.88 49.21 49.21 53.99 50.88


3 1.93 2.08 2.12 2.24 2.21

7 2.33 2.5 2.66 3.01 2.82

28 2.97 3.04 3.25 3.44 3.43


3 3.84 3.91 4.17 4.73 4.68

7 5.07 5.12 5.61 6.02 5.85

28 6.39 6.45 7.01 7.4 7.18

For durability study the cubes, cylinders, prisms which are cured in water for 28

days are immersed in acid for 30 days and tested. The strength is compared with 28

days strength of water cured specimens.

Table 9 Strength characteristics of Acid Treated M20 Grade specimens

Testing

M20 with

0% M-

Sand

M20 with

20% M-

Sand

M20 with

40% M-

Sand

M20 with

60% M-

Sand

M20 with

100% M-

Sand


28 days 40 42.92 44.07 48 45.77

Acid treated 37.01 39.97 42.33 45.97 43.09


28 days 2.93 3.11 3.14 3.67 3.48

Acid treated 2.65 2.88 2.97 3.52 3.32


28 days 5.78 5.95 6.14 6.82 6.41

Acid treated 5.06 5.28 5.58 6.195 5.9

Table 10 Strength characteristics of Acid Treated M30 Grade specimens

Testing

M20 with

0% M-

Sand

M20 with

20% M-

Sand

M20 with

40% M-

Sand

M20 with

60% M-

Sand

M20 with

100% M-

Sand


28 days 48.88 49.21 49.21 53.99 50.88

Acid treated 44.88 45.67 47.03 50.42 47.97


28 days 2.97 3.04 3.25 3.44 3.43

Acid treated 2.14 2.27 2.46 2.97 2.92


28 days 6.39 6.45 7.01 7.4 7.18

Acid treated 5.02 5.08 5.44 6.32 6.08



Figure 1 compaction factor test

Figure 2 vee bee time apparatus

Figure 3 acid treatment of specimens



Figure 4 acid treated specimens

6. RESULTS AND DISCUSSIONS

The slump, compaction factor is decreasing and vee-bee time is increasing as the

percentage of replacement of natural sand by manufactured sandis increasing. The

percentage of admixture required for making the mixes to a slump of 40mm to 80mm

is also increasing as the percentage of replacement of natural sand by manufactured

sandis increasing.

The Compressive strength, split tensile strength, flexural strengths has showed

increase in strength when the natural sand is replaced by manufactured sand. The 28

day compressive strength, split tensile strength and flexural strength of M20 and

M30for all the mixes were shown in the graphs below.

Figure 5 compressive strength of M20 and M30 grade concrete with replacements

From figure-5 we can infer that the increase in compressive strength for M20grade

concrete is 0%, 7.3%, 10.17%, 20%, 14.42% and M30 grade is 0%, 0.67%, 3.66%,

10.45%, 4.09% respectively for 0%, 20%, 40%, 60% and 100% replacement of

natural sand with manufactured sand.

0

10

20

30

40

50

60

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand

M20 with 100% M-Sand

M20

M30



Figure 6 Split tensile strength of M20 and M30 grade concrete with replacements

From figure-6 we can infer that the increase in split tensile strength for M20grade

concrete is 0%, 6.14%, 7.16%, 25.04%, 18.56% and M30 grade is 0%, 2.35%, 9.42%,



Figure 7 Flexural strength of M20 and M30 grade concrete with replacements

From figure-7 we can infer that the increase in split tensile strength for M20grade

concrete is 0%, 2.94%, 6.22%, 18.11%, 10.89% and M30 grade is 0%, 0.93%, 6.39%,



From the results it is clearly evident that 60% replacement of natural sand by

manufactured sand has given good strength compared to all other replacements. The

increase in strength is high in every M20grade mix because the mix is aggregate

dominant where as M30grade is mortar dominant.

The Compressive strength, split tensile strength, flexural strengths were

decreasing when the acid treated specimens were tested. The strength of acid treated

specimens is compared with 28 day strengths of M20 and M30grade mixes for all the

mixes were shown in the graphs below.

0

0.5

1

1.5

2

2.5

3

3.5

4

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


M20

M30

0

1

2

3

4

5

6

7

8

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


M20

M30



Figure 8 compressive strength of M20 concrete with replacements

From figure-8 we can infer that the decrease in compressive strength for M20grade

concrete is 8.07%, 7.38%, 3.94%, 4.44%, 6.21% respectively for 0%, 20%, 40%, 60%

and 100% replacement of natural sand with manufactured sand.

Figure 9 split tensile strength of M20 grade concrete with replacements

From figure-9 we can infer that the decrease in split tensile strength for M20grade

concrete is 9.71%, 7.45%, 5.62%, 4.08%, 4.51% respectively for 0%, 20%, 40%, 60%

and 100% replacement of natural sand with manufactured sand.

40.0 42.9 44.1

48.0 45.8

37.0 40.0

42.3 46.0

43.1

0

10

20

30

40

50

60

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


28 day strength

acid treated strength

2.9 3.1 3.1

3.7 3.5

2.7 2.9 3.0

3.5 3.3

0

0.5

1

1.5

2

2.5

3

3.5

4

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


28 day strength




Figure 10 Flexural strength of M20 grade concrete with replacements

From figure-10 we can infer that the decrease in compressive strength for

M20grade concrete is 12.45%, 11.26%, 9.12%, 9.15%, 7.95% respectively for 0%,

20%, 40%, 60% and 100% replacement of natural sand with manufactured sand.

From the results it is evident that60% replacement of manufactured sand with

natural sand has given good resistance to acid treatment for all the mixes of M20

grade.

Figure 11 compressive strength of M30 grade concrete with replacements


M30grade concrete is 8.18%, 7.19%, 7.18%, 6.66%, 5.71% respectively for 0%, 20%,

40%, 60% and 100% replacement of natural sand with manufactured sand.

5.8 6.0 6.1

6.8 6.4

5.1 5.3 5.6

6.2 5.9

0

1

2

3

4

5

6

7

8

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


28 day strength


48.9 49.2 49.2

54.0 50.9

44.9 45.7 47.0 50.4

48.0

0

10

20

30

40

50

60

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


28 day strength




Figure 12 split tensile strength of M30 grade concrete with replacements

From figure-12 we can infer that the decrease in split tensile strength for M30grade

concrete is 27.94%, 25.32%, 24.3%, 13.66%, 14.88% respectively for 0%, 20%, 40%,

60% and 100% replacement of natural sand with manufactured sand.

Figure 13 Flexural strength of M30 grade concrete with replacements

3.0 3.0 3.3

3.4 3.4

2.1 2.3

2.5

3.0 2.9

0

0.5

1

1.5

2

2.5

3

3.5

4

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


28 day strength


6.4 6.5

7.0 7.4

7.2

5.0 5.1 5.4

6.3 6.1

0

1

2

3

4

5

6

7

8

M20 with 0% M-Sand

M20 with 20% M-Sand

M20 with 40% M-Sand

M20 with 60% M-Sand


28 day strength





M20grade concrete is 21.4%, 21.2%, 22.39%, 14.59%, 15.32% respectively for 0%,

20%, 40%, 60% and 100% replacement of natural sand with manufactured sand.

From the results it is evident that60% replacement of manufactured sand with

natural sand has given good resistance to acid treatment for all the mixes of M30

grade.

7. CONCLUSIONS

Results were analyzed to derive useful conclusions regarding the workability,

strength, durability, characteristics of concrete with replacement of natural sand with

manufactured sand in different proportions for M20 and M30 grades. The following

conclusions may be drawn from the study

The manufactured sand is a best alternative for natural sand in terms of strength and

durability.

Manufactured sand yields mixes with low work ability as the particle shape is angular

and it can be compensated by adding admixtures to the mix.

The 60% replacement of natural sand by manufactured sand yielded good

compressive strength, split tensile strength, flexural strength for M20 and M30 grade

concrete compared to other proportions of mixes.

The 60% replacement of natural sand by manufactured sand has shown good

resistance to acid treatment in compressive strength, split tensile strength, flexural

strength for M20 and M30 grade concrete compared to other proportions of mixes.

8. NOTATIONS

Fe – iron

Ca – calcium

Al – aluminum

Si – silicon

HCL – hydrochloric acid

CaCl2 – Calcium chloride

Ca (OH) 2 – calcium hydroxide

C-S-H – Calcium Silicate Hydrates

[Al (OH)4]-- Tetrahydroxyaluminate ion

REFERENCES

[1] Hudson, B. P., Manufactured Sand for concrete, The Indian concrete Journal,

May 1997, pp.237-240

[2] Ilangovana R., Mahendrana

N. and Nagamanib. K strength and durability

properties of concrete containing quarry rock dust as fine aggregate ARPN

Journal of Engineering and Applied Sciences 3(5), OCTOBER 2008 ISSN 1819-

6608

[3] Nagabhushana and Sharada bai. H , Use of crushed rock powder as replacement

of fine aggregate in mortar and concrete, Indian Journal of Science and

Technology 4(8) Aug 2011 ISSN: 0974- 6846

[4] Saeed Ahmad and Shahid Mahmood effects of crushed and natural sand on the

properties of fresh and hardened concrete



[5] Sivakumar. A and Prakash M. Characteristic studies on the mechanical properties

of quarry dust addition in conventional concrete Journal of Civil Engineering and

Construction Technology 2(10), pp. 218-235, October 2011 ISSN 2141-2634

©2011 Academic Journals

[6] Veera Reddy.M Investigations on stone dust and ceramic scrap as aggregate

replacement in concrete international journal of civil and structural engineering

1(3), 2010

[7] Venu malagavelli High performance concrete with GGBS and Robo sand,

International Journal of Engineering Science and Technology 2(10), 2010, pp

5107-5113

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