Industrial Engineering Journal

ISSN: 0970-2555
Volume : 52, Issue 1, No. 1, January 2023

EXPERIMENTAL EVALUATION OF M35 GRADE CONVENTIONAL CONCRETE BY

SUPPLEMENTING NATURAL FIBERS, FOUNDRY SAND AND SEA SAND AS PARTIAL
REPLACEMENTS

Mohammed Shafan Ahmed, M.tech Student, Kallam Haranadhareddy Institute of Technology, India.
Dr. B. Sarath Chandra Kumar, Professor, Kallam Haranadhareddy Institute of Technology, India.
Dr. M. Satish Kumar, Professor & HOD, Kallam Haranadhareddy Institute of Technology, India.

Abstract-Present urbanization required a huge variety of concretes and minimized effects of newly
developed composite materials. This development leads to adverse effects on the surrounding
environment. As a part of environmental concern, we have to minimize the negative effects. The use of
fine aggregate in the construction industry is more. Therefore, the use of river sand can be replaced with
other materials to protect the environment of the river as well as prevent erosion and flood, in My present
research paper is similar to this, based on the recycling technique I used to do materials replacements of
natural fibers and waste foundry sand & sea sand are the major partial replacements of fine aggregate and
grade of concrete are M-35.After the preparation of M-35 Grade concrete, it should be validated with
conventional concrete. The major tests are conducted on M-35 grade hardened concrete, which are
Concrete cube tests, Cylinder Test & flexural tests. After the test results are verified with referenced
documents and satisfactory results are obtained, the complete discussions and results are listed separately
in further chapters.

Keywords: Recycled Materials, Natural fibers, M-35grade, Foundry waste, Foundry sand.

1. INTRODUCTION
By volume, aggregate accounts for about 80% of the total weight of concrete. In the manufacturing of
concrete, both fine and coarse aggregates are used. With startling rapidity, the use of sand as a fine
aggregate in the building sector has risen to unprecedented heights. Natural river sand is in short supply
in the sector, which is making it difficult to meet the growing demand for the material. In order to address
this dilemma, the building industry has developed alternatives such as synthetic sand, robo sand, rock
dust, and other materials such as gravel. Another option to this is the utilisation of waste material in the
construction of concrete structures. Sedimentary sand and waste foundry sand are two types of waste
materials produced by the ferrous and non-ferrous metal casting industries, respectively. It is possible that
the use of such a material in concrete will help to reduce the environmental problems associated with
waste foundry sand and other resources, as well as make concrete manufacturing more cost-effective.
Sand is essential in the building sector on a large scale. It is a significant ingredient in the manufacture of
mortar and concrete, and it plays an important role in the design of concrete mixes. River sand is in low
supply these days as a result of erosion and other environmental concerns. The building sector would be
adversely affected by the lack of river sand, and as a result, it is necessary to develop innovative alternative
materials to replace river sand. Many researchers are working to develop alternative materials to sand,
with sea sand being one of the most commonly used substitutes for sand. The M35 grade of concrete was
used in the current investigation. Natural sand was largely replaced by sea sand in quantities ranging from
0 to 40%.
A natural fibre is one that is neither synthetic nor manufactured, and this is the simplest meaning of the
term. They may be derived from either plants or animals as sources. The utilisation of natural fibres

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Volume : 52, Issue 1, No. 1, January 2023

derived from both renewable and non-renewable resources, such as oil palm, sisal, flax, and jute, to
manufacture composite materials has received a great deal of interest in recent decades, particularly in the
field of composite materials. Base fibres (jute, flax, ramie, hemp, and kenaf), seed fibres (cotton), leaf
fibres (sisal, pineapple, banana, and abaca), grass and reed fibres (rice, corn, and wheat), and core fibres
(hemp, kenaf, and coir), as well as all other kinds of cellulose fibres, are produced by plants that produce
cellulose fibres (wood and roots).

2. LITERATURE REVIEW
Naik et al. (1987) He performed research on using waste foundry sands in concrete, that is, concrete that
makes use of discarded foundry sands in lieu of a fine mixture. The proportions of a manipulated concrete
blend have been adjusted to attain a compressive energy of 38 MPa after 28 days. Other concrete mixes
have been balanced such that clean/new foundry sand and used foundry sand have been substituted for 25
percent and 35 percent, respectively, of the same old concrete sand weight. The compressive strength,
tensile power, and modulus of elasticity of the concrete have been measured and analysed to determine its
overall performance. At 28 days, used foundry sand-containing concrete had values that were 20-30%
lower than non-used foundry sand-containing concrete.Clean/new foundry sand became utilised in 25
percent and 35 percent of the concrete mixes, respectively, and the compressive electricity became almost
equal to that of the control blend.
Reddietal.(1995):The compressive energy of stabilized foundry sands diminishes because the
replacement percentage of foundry sand inside the mixes grows, and the strength is attained significantly
faster with fly ash than with cement, consistent with his findings. Cement and fly ash mixes were created
by substituting foundry sand for silica sand at numerous probabilities (zero percent, 25 percent, 50 percent,
seventy-five percent, and a hundred percent) of the original amount of silica sand. As a result of the failure
of the first studies using class F fly ash, which lacked the cementitious qualities important to making a
solid mix, the next trials were restricted to magnificence C fly ash by myself. It was determined that the
water-to-cementitious-binder ratio needed to be one in the case of Portland cement and one-third in the
case of fly ash in this observe. The samples were constructed using PVC pipes measuring 2.85 cm in
diameter and 5.72 cm in length. The sand and binder combos have been poured into those pipes, which
were then vibrated on a vibrating desk to eliminate any air pockets that may have formed. Compressive
strengths were measured after 3, 7, 14, 28, and 56 days for each of the replacement tiers to be able to
assess the impact of curing time at the very last compressive strength. The clay-bonded foundry sand had
an extra effect on the strength of the stabilised combinations than the resin-bonded foundry sands did on
them. A similar finding has been made in the area of fly ash stabilisation. In each of the examples of fly
ash and cement, the large drop of strength that happens with the growth of clay in a certain foundry sand
substitute is readily apparent. The electricity of cement-stabilized mixtures develops at a far slower rate
than that of fly ash-stabilized mixes. Although it took just seven days to complete therapy, the cement-
stabilized RBS only executed 30% of its peak energy, but its fly ash counterpart obtained 80% of its peak
power.

3. PROPERTIESOFMATERIALS
Properties of Foundry Sand:
Various environmental issues are caused by the trash created by the industrial sector. As a result, the
importance of reusing this waste material may be underlined. Foundry sand is a high-quality silica sand
that is produced as a by-product of the manufacture of both ferrous and nonferrous metal casting

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industries, and it is used in a variety of applications. Because of its excellent heat conductivity, foundry
sand has been used as a moulding and casting medium for hundreds of years now. For foundry sand to
have certain physical and chemical qualities, the kind of casting process used and the industrial sector
from which it comes are important considerations to bear in mind. Sands from the moulding process are
recycled and reused numerous times throughout the casting process. It is inevitable that recycled sand will
deteriorate to the point that it can no longer be utilised in the casting process at some time in the future.
Upon reaching this phase, the old sand is removed from the cycle as a by-product, and fresh sand is
injected, resulting in the cycle starting again from the beginning.
There are two primary kinds of binder systems used in metal casting, and the foundry sands are divided
into two categories based on the type of binder system employed: clay-bound systems (green sand) and
chemically-bonded systems. They are both suited for beneficial use, yet they have distinct physical and
environmental properties that distinguish them from one another. During the past several decades, a great
deal of investigation has been undertaken into the mechanical, chemical, and durability characteristics of
foundry sand. However, the investigation of the strength and durability features of foundry sand concrete
receives little attention in the literature.
PHYSICAL PROPERTIES OFFOUNDRYSAND
Characteristics Values
BulkRelativeDensity 2592kg/m3

Absorption 0.43 %

MoistureContent 0.1 – 9.8

ClayLumpsandFriableParticles 1 – 42

Coefficientofpermeability 10-3–10-6cm/s

PlasticLimit Non-Plastic
Specificgravity 2.49
TABLE:1PHYSICALPROPERTIESOFFOUNDRYSAND
CHEMICALPROPERTIESOFFOUNDRYSAND
Constituents Value Constituents Value
Sio2 67.21 Na2O 0.48
Al2O3 4.28 K2O 0.46
Fe2O3 7.32 P2O5 0.00
CaO 0.15 Mn2O3 0.12
MgO 0.23 SrO 0.19
S03 0.89 Tio2 0.48
Lossofignition 16.25

TABLE:2CHEMICALPROPERTIESOFFOUNDRYSAND

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4. TESTS ON MATERIALS
Current paper deals with the used materials and conducted laboratory tests on cement, Fine aggregate,
coarse aggregate, Replacement Materials

CEMENT:
Generally speaking, cement is a binder, which means it is a substance that sets and hardens on its own and
may be used to bind other materials together as a binding agent. Cement is generally composed of
components in the form of limestone, chalk, and marl, as well as argillaceous minerals, as well as other
additives. It is necessary to use standard Portland cement grade 53.

FINENESS OFCEMENT:
This test gives the percentage amount of course material present in the cement.
If content of coarse material greaterthan10%, the cement should not be used.
 Procedure and observation:
 Takenthe100grams(W1) of ordinary Portal and cement in a basin and spread it on the
90µm sieve.
 Shakenitaround10-15minutes.
 The weight residue on the sieve (W2) was measured
 Percentage ratio of W2 to W1gives the residue of the cement.
 Result

CONSISTENCY OF CEMENT:
This test is performed to know the amount of water required to form a cement paste of standard
consistency. Standard consistency is about 30% for OPC.
 Procedure and observation:
 400grams of cement was taken and 25% of water was added to it.
 The cement paste was placed in the mould and placed it under the needle of vicat apparatus.
 Then the plunger released slowly, so needle is penetrated in to the paste.
 Reading on the vicat apparatus was noted.
 Another mix was prepared by increasing the percentage of water and the above procedure was
repeated for the different mould shaving different water percentages.
 The penetration value was tabulated below for the different percentages of water.
 The water content at which reading will shows the penetration of 5 to 7mm on vacate apparatus is the
 normal consistency of cement.

INITIAL AND FINAL SETTING TIME OFCEMENT:

Initial setting time:
This is the time period between the time water is introduced to the cement and the time when partial loss
of plasticity occurs, which is measured by the depth to which a standard test needle penetrates the block
(5 mm from the bottom). The first setup time should be no less than 30 minutes.
Final setting time:
The time of interval between the time when water is added to the cement and time of
complete loss of plasticity i.e., in standard test needle can’t penetrates the block since paste hardened.

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Final setting time should not be more than 600min.

 Procedure and observation:
 400grams of cement was taken,0.85times the normal consistency of water was added to the cement and
starts the stop watch.
 Cementpastewasplacedinthemouldanditwasplacedundertheneedleofvicatapparatus.
 Plunger was released slowly, so needle is penetrated in to the paste.
 Reading on the vicat apparatus was noted and the needle lifted up and needle was released after
sometime.
 The time at which reading will shows the penetration of 5mm from bottom on vacat apparatus was
noted.
 Another mix was prepared and starts the stopwatch. Needle of vicat apparatus was changed for final
setting time.
 Same procedure was repeated and measured the time at which needle can’t able to enter ateinto the
paste.

SPECIFIC GRAVITY OF CEMENT:

Specifically, specific gravity may be defined as the relationship between the weight of a given volume of
material at a standard temperature and the weight of an identical amount of distilled water at the same
specified temperature.
 Procedure and observation:
 Pycnometer is used to measure the specific gravity of the Cement.
 Empty weight of the pycnometer(W1) was measured.
 Measured the weight of the pycnometer after1/4th of its volume is filled with Cement(W2).
 Measured the weight of pycnometer which contain 1/4th volume of cement and kerosene up to mark
(W3).
 Pycnometer was filled with water up to the mark and measured its weight (W4).

5. TEST REPORTS
After casting of cube specimens, I conducted tests on hardened concrete and correlated with Indian
standard limits and interpreted
TEST: 1

COMPRESSIVESTRENGTHONCONCRETECUBES:
The uniaxial compressive strength of a material is defined as the value of uniaxial compressive
stress attained by the material when it totally fails. As part of this research, cube specimens with
dimensions of 150 millimetres by 150 millimetres by 150 millimetres are examined in line with
IS: 516 – 1969 [Method of test for concrete strength]. The compression testing was carried out
using compression testing equipment with a capacity of 300 KN. The machine is equipped with a
control valve that allows the operator to regulate the pace of loading. The quipment has been
calibrated in accordance with the established norms. The plates have been cleaned, the oil level
has been checked, and the machine has been prepared in every way for testing.
After 28 days of curing, the cube specimens were taken from the curing tank and thoroughly
cleaned to eliminate any remaining surface water. The specimens were placed on the swivelling

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head of the machine in such a way that the weight was applied at the centre of the specimens.
The bearing surfaces are put on the specimen's flat surfaces, which act as bearing surfaces. By
spinning the handle, the top plate was brought into contact with the specimen on the bottom
plate. The oil pressure valve was closed, and the machine was turned on for the first time. It was
possible to maintain a constant loading rate of 140 kg/cm2/min. It was determined what the maximum
load to failure was at which the specimen broke and the pointer began to move back. The test
was repeated for each of the three specimens, and the mean of the three values was selected to
represent the average strength. The compressive strength test on concrete containing various sizes
of coarse aggregate has been carried out in the current inquiry. The M35 grade was examined on
the 7th and 28th days
TEST REPORT FOR SEVEN DAYS SPECIMENS
 Compressive strength of normal concrete mix[M-35grade] for7days
 Compressive strength Graph of normal concrete mix [M-35grade] for7days

S.NO CUBEID %OFREPLACEMNT (%) 7 DAYS N/mm2

1 N-MIX 0% 26.01
2 N-MIX 0% 25.97
3 N-MIX 0% 25.98
4 N-MIX 0% 25.90
5 N-MIX 0% 26.00
TABLE 20: COMPRESSIVE STRENGTH 28 DAYS NORMAL MIX

7 DAYS COMPRSSIVE STRENGTH

26.02 26.01 26
26.00 25.98
25.97

25.98 0 0 0 0 0
7DAYSN/SQ. 26.01 25.97 25.98 25.9 26
25.96
MM 19.9
25.94

25.92

25.9

7 DAYS N/SQ.MM Linear (7 DAYS N/SQ.MM)

FIG 5: COMPRESSIVE STRENGTH GRAPH OF NORMAL MIX

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PROPERTIESOFSEASAND:
In this work, sea sand is used to partially replace fine aggregate as a fine aggregate replacement. It was
obtained from Bapatla beach, which is located inside Zone IV. The following are the specific gravity,
fineness modulus, and sieve analysis results for sea sand:
S.no Property Testresults
1 SpecificGravity 2.16
2 Finenessmodulus 0.90
3 Zone 4
4 pHvalue 8.2
TABLE:3PHYSICALPROPERTIESOFSEASAND

CHEMICAL PROPERTIESOFSEASAND
Chlorides are a kind of soluble mineral component that is dissolved by water as it passes through the
earth's surface. Chlorides are often found in sea sand, and they are toxic. As recommended by the World
Health Organization, the maximum permissible chloride content in drinking water ranges between 250
and 1000 mg/l. Sea water may be tested for chloride concentration by titrating it with a standard silver
nitrate solution, which is made using potassium dichromate.
Watersamples River sand Sea Sand without Seasandwithwasinmg/lit
inMg/Lit wasin mg/lit
Amountofchloridecontent 238 419 269
TABLE:4CHEMICALPROPERTIESOFSEASAND
PHVALUE:The pH of water is a measure of how acidic or basic it is. The numbers range from 0 to 14,
with 7 representing neutrality. Having a pH of less than 7 denotes acidity, whereas having a pH of greater
than 7 suggests baseness. The pH of water is really a measure of the relative number of free hydrogen and
hydroxyl ions present in the solution. A pH metre is an electronic device that consists of a particular bulb
that is sensitive to zero. The light from the bulb is amplified and fed to an electronic metre that is attached
to the bulb and measures and displays the pH value. In comparison to the pH sheets, it provides more
exact readings.
HARDNESS: Hardness is a feature of water that hinders the creation of lather or foam when the water is
combined with soap and other ingredients. It is most often induced by the presence of divalent metallic
ions such as calcium and magnesium. Hardness is commonly described as the calcium carbonate
equivalent of the presence of calcium and magnesium ions in water, and it is represented in milligrammes
per litre of water. Hardness may be classified into two categories.

CONCLUSIONS
To obtain the mechanical properties we run two tests on concrete cubes. A total of 106 Concrete cubes
were casted and obtained reports for 7 &28 days conducted tests are compressive strength and UPV tests.
 For normal concrete mix seven days ‟strength achieve dissimulative of 61% which is accurate based on
Indian standards
 For twenty-eight days ‟concrete mix strength achieves dissimulative of 99%which is also accurate based
on Indian standards

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 Finally conducted UPV test on Concrete Test cubes8 cubes are Obtained result of„ GOOD ‟Quality of
concrete
 further replacements up to 15%-25% was not defined by past reviewers and researchers,
 My present research work is limited up to 12 % of replacements of Foundry sand /Sea sand/Natural
fibers.

References:
1. M.S. Shetty, ConcreteTechnologyandPractice,7th edition, Chand and company limited.
2. IS:10262-2009---Recommended guidelines for concrete mix design.
3. SP:23-1982---Handbook on concrete mix design.
4. Journal of Engineering Trends and Technology (IJETT) Volume 14
5. R.N. Singh.Flexural Behaviour of Notched Coir Reinforced Concrete P. Paramasivam,G.
K. Nathan and N. C. Das Gupta.
6. Fiber Reinforced Corrugated Slab. The International Journal of Cement Composite and
Lightweight Concrete, Vol. 6, No.1, Feb.
7. H.E. Gramand P. Nimityongskul. Durability of Natural Fiber in Cement-Based Roofing Sheets.
Journal of Ferro-Cement Vol. 17, No. 4, Oct.1987.

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