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1. VISVESVARAYA TECHNOLOGICAL UNIVERSITY BELAGAVI – 590 018 “EXPERIMENTAL STUDY ON REPLACEMENT COARSE AGGREGATE BY SINTERED FLY ASH AGGREGATE”

2. CONTENTS 1 Introduction 2 Literature review 3 Materials 4 Materials properties 5 Methodology 6 Test on concrete for varying percentage of Sintered Fly ash Aggregates 7 Conclusions 8 Scope of future work 9 Project photos

3. INTRODUCTION : Concrete is a widely used source of construction material, and in recent years, researchers have been looking into various ways of making concrete stronger and more durable to reduce the amount of concrete needed. In this project, we intend to evaluate the effectiveness of Sintered fly ash as an additive that increases the strength and durability of concrete. Sintered fly ash aggregate is an artificial aggregate made by burning pulverized coal in electric generation power plant waste . The lightweight concrete produced using sintered fly ash aggregates shows a similar characteristic of normal concrete and is also good in durability.

4. LITERATURE REVIEW : AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 1. DILIP KUMAR (2018) Replacement of Coarse Aggregate with Sintered Fly Ash Aggregates for Making Low-Cost Concrete This research establishes a relationship of bulged diameter with densification and hydrostatic stress in forming of sintered fly ash. The maximum flexural strength of 11.16 N/mm2 is found at 30% replacement of Sintered fly ash aggregate in concrete, while the minimum strength of 2.10 N/mm2 was attained at 50% replacement of Sintered fly ash aggregate in concrete The possibility exists for the partial replacement of coarse aggregate with Sintered fly ash aggregate that produced in thermal power plants waste materials. Sintered fly ash is compatible with the cement. Uses and applications of sintered fly ash as coarse aggregate can reduce the cost of construction Materials and it is useful in environmental protection.

5. AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 2. MANU S NADESAN (2018) Materials and Methods of Sintered Fly Ash Light Weight Aggregate Production The structural concrete produced using sintered fly ash aggregate have to ensure certain mechanical and durability characteristics. The manufacturing process and control parameters of sintered fly ash aggregate also reviewed The use of sintered fly ash aggregate to produce structural lightweight aggregate concrete The literature shows absorption capacity between 0.7 and 33.9%, commercially available aggregates possess water absorption capacity around 18%. Aggregates are spherical in shape having specific gravity varies from 1.33 to 2.35 and loose bulk density between 765 and 936 kg/m3.

6. AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 3. SIVAKUMAR (2018) Pelletized Fly Ash Light Weight Aggregate Concrete: A Promising Material. The production of concrete requires aggregate as an inert filler to provide bulk volume as well as stiffness to concrete. Crushed aggregates are commonly used in concrete which can be depleting the natural resources and necessitates an alternative building material The fly ash aggregate produced by pelletization can be an effective aggregate in concrete production. In the near future the depletion of the nature resources for aggregate can be suitably compensated from the fly ash aggregate.

7. AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 4. M.K DIPTI KANTA ROUT (2018) Investigation on the Development of Light Weight Concrete with Sintered Fly Ash Aggregate and Activated Fly Ash in Blended Cement The use of activated fly ash in blended cement and sintered fly ash aggregate in concrete as a partial replacement of granite aggregate has been examined. The present investigation following conclusions Presence of lime bearing complex silicate impart better pozzolanic property than those due to the presence of crystalline quartz and mullite phases

8. AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 5. PURUSH OTHAMAN (2020) Experimental Study on Mechanical Properties of Sintered Fly Ash Aggregate in Concrete This lookup work affords the effects of an experimental work on the outcomes of sintered fly ash combination in concrete. It is proposed to change partially, the sintered fly ash mixture (SFAA) in exclusive proportion for the traditional aggregate. It is determined that the expand in the share of sintered fly ash combination in concrete offers accurate workability and mechanical properties. Hence it is concluded that there is discount in lifeless load of the specimens. Obtained consequences endorse the SFAA concrete has scope for structural application.

9. AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 6. PANKAJ DHEMLA (2021) Experimental Investigation of Light Weight Concrete Using Sintered Fly Ash Aggregates The aggregates were mixed in various proportions of 80:20, 60:40, 40:60, and 20:80, to study the fresh and harden properties of LWC. Results showed that LWC prepared with finer aggregate (4-8mm) reduces the bulk density and enhances the mechanical properties. From above investigation that of smaller SLWA in LWC enhance the properties of concrete but simultaneously density also increases.

10. AUTHORS TITLE OF THE PAPER DESCRIPTION CONCLUSIONS 7. B RANJITH BABU (2022) Prediction of Compressive Strength of Sintered Fly Ash Aggregate Concrete Using Artificial Neural Networking In this study, a high strength-lightweight concrete of 50 MPa compressive strength was developed using an artificial neural network through Mat Lab programming Fly ash is processed systematically into pelletized aggregates and heated to temperatures up to 1500 degrees Celsius The predicted compressive strength was only for the short term (28 days) and not for the long term (56 days and later). The long-term compressive strength in the will be higher, due to its pozzolanic additives such as silica fume and fly ash.

11. MATERIALS Fine aggregates. Coarse aggregates. Cement. Water. Sintered fly ash . Fig. Sintered fly ash

12. MATERIALS PROPERTIES Properties Value Specific Gravity 2.6 Water absorption 1.57% Fineness modulus 3.1 (zone II) Surface moisture Nill Bulk density kg/m 3 COARSE AGGREGATE Properties Value Specific Gravity 2.76 Bulk Density (Loose) 1520kg/m 3 Bulk Density (Compacted) 1560kg/m 3 Water Absorption 0.4 Aggregate Impact Value 14.44% Aggregate Crushing Value 12.22% CEMENT Properties Value Specific Gravity 3.12 Normal Consistency 29% Initial Setting time 65min Final Setting time 275min Fineness 330kg/m 2 Soundness 2.5mm Bulk Density m SINTERED FLY ASH Properties Value Specific Gravity 1.395 Water Absorption for 24 (%) 16.8 Loose bulk density 830 Rodded bulk density 895 Fineness modulus 1.91 Aggregate impact value 27.78 Aggregate crushing value 15.63 FINE AGGREGATE

13. METHODOLOGY: The general method used for conducting test on the strength aspects is by casting concrete specimens and conducting the test as per the code provision.

14. TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATES COMPRESSION TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATE FOR 7 DAYS OF CUBE   SL.NO VARYING COMBINATION OF SINTERED FLY ASH AGGREGATE   STRENGTH IN N/ mm 2   AVERAGE IN N/ mm 2 1   0% 7.9 8.1 2 8.1 3 8.3 4   10%SFA+90%CA 7.3 7.4 5 7.8 6 7.1 7   20%SFA+80%CA 7.9 7.7 8 7.5 9 8.3 10   30%SFA+70%CA 6.1 5.8 11 5.9 12 5.6

15. COMPRESSION TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATE FOR 14 DAYS OF CUBE   SL.NO VARYING COMBINATION OF SINTERED FLY ASH AGGREGATE   STRENGTH IN N/mm2   AVERAGE IN N/mm2 1   0% 15.9 15.4 2 14.8 3 15.6 4   10%SFA+90%CA 15.11 14.92 5 13.77 6 15.88 7   20%SFA+80%CA 15.1 15.06 8 14.9 9 15.2 10   30%SFA+70%CA 15.55 12.79 11 13.95 12 8.88

16. COMPRESSION TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATE FOR 28 DAYS OF CUBE   SL.NO VARYING COMBINATION OF SINTERED FLY ASH AGGREGATE   STRENGTH IN N/ mm 2   AVERAGE IN N/ mm 2 1   0% 23.1 23.50 2 23.9 3 23.5 4   10%SFA+90%CA 23.55 21.84 5 19.11 6 22.86 7   20%SFA+80%CA 22.13 21.89 8 21.11 9 22.45 10   30%SFA+70%CA 14.88 19.07 11 21.55 12 20.80

17. COMPRESSION STRENGTH OF CONVENTIONAL CONCRETE AND OPTIMUM CONCRETE MIX OF CUBE SL. NO DAYS OF CURING CONVENTIONAL CONCRETE OPTIMUM MIX Compressive strength in KN / m 2 Avg in KN / m 2 Compressive strength in KN / m 2 Avg in KN / m 2 1   7 7.9 8.1 7.9 7.7 2 8.1 7.8 3 8.3 7.1 4   14 15.9   15.4     15.1 15.06       5 14.8 14.9 6 15.6 15.2 15.6 7                     28   23.1   23.50   22.13   21.89   8 23.9 21.11 9 23.5 22.45

18. COMPRESSION TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATE FOR 7 DAYS OF CYLINDER   SL.NO VARYING COMBINATION OF SINTERED FLY ASH AGGREGATE   STRENGTH IN N/ mm 2   AVERAGE IN N/ mm 2 1   0% 7.9 8.16 2 8.5 3 8.1 4   10%SFA+90%CA 6.16 7.05 5 7.92 6 7.02 7   20%SFA+80%CA 8.18 8.00 8 7.35 9 8.48 10   30%SFA+70%CA 5.37 4.9 11 3.39 12 5.94

19. COMPRESSION TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATE FOR 14 DAYS CYLINDER   SL.NO VARYING COMBINATION OF SINTERED FLY ASH AGGREGATE   STRENGTH IN N/ mm 2   AVERAGE IN N/ mm 2 1   0% 16.1 15.83 2 15.9 3 15.5 4   10%SFA+90%CA 12.9 12.86 5 13.1 6 12.6 7   20%SFA+80%CA 13.5 13.83 8 13.8 9 14.2 10   30%SFA+70%CA 10.75 9.80 11 9.90 12 8.77

20. COMPRESSION TEST ON CONCRETE FOR VARYING PERCENTAGE OF SINTERED FLY ASH AGGREGATE FOR 28 DAYS CYLINDER   SL.NO VARYING COMBINATION OF SINTERED FLY ASH AGGREGATE   STRENGTH IN N/ mm 2   AVERAGE IN N/ mm 2 1   0% 24.1 23.23 2 23.5 3 22.9 4   10%SFA+90%CA 21.5 20.5 5 19.3 6 20.7 7   20%SFA+80%CA   22.6 21.76 8 20.9 20.9 9 21.8 10   30%SFA+70%CA 13.20 12.78 11 12.14 12 13.01

21. COMPRESSION STRENGTH OF CONVENTIONAL CONCRETE AND OPTIMUM CONCRETE MIX OF CYLINDER SL. NO DAYS OF CURING CONVENTIONAL CONCRETE OPTIMUM MIX Compressive strength in KN / m 2 Avg in KN / m 2 Compressive strength in KN / m 2 Avg in KN / m 2 1     7 7.9     8.16 8.18     8.00 2 8.5 7.35 3 8.1 8.48 4     14 16.1     15.83   13.5     13.83   5 15.9 13.8 6 15.5 14.2 7   28   24.1   23.23   22.6   21.76   8 23.5 20.9 9 22.9 21.8

22. CONCLUSIONS From the present Investigation the following conclusions have been drawn   With the increase in replacement % of SFA the slump value also increases in order to maintain a constant slump super palletizers may be adopted in order to a maintains a required workability aspect. Compressive strength of concrete increases with the in replacement % of SFA. Further increase is replacement % of SFA results is decrease is strength. The optimum replacement % of SFA was found to be 20 %. Finally, it can be concluded that use of SFA as a replacement CA can be effectively used in construction purpose however the above observation is based as source of materials and the conclusions are limited to the materials investigated in the study.

23. SCOPE OF FUTURE WORK     1. Long-Term Durability Studies Creep and Shrinkage: Investigate the long-term creep and shrinkage characteristics of lightweight concrete with sintered fly ash aggregates. Environmental Resistance : Assess the durability of such concrete in various environmental conditions, including freeze-thaw cycles, sulfate attack, and carbonation. 2. Optimization of Mix Design Proportioning: Explore the optimal proportioning of sintered fly ash aggregates to achieve the best balance between strength, workability, and density. 3. Economic Feasibility Cost Analysis: Perform a detailed cost-benefit analysis comparing lightweight concrete with sintered fly ash aggregates to conventional concrete.

24. PROJECT PHOTOS

25. COMPRESSION STRENGTH OF CUBES AND CYLINDERS

26. T H A N K Y O U