SIDDAGANGA INSTITUTE OF TECHNOLOGY, TUMKUR (572103)

(An Autonomous Institute under Visveshwariah Technological University,Belagavi)

Synopsis (Phase-2)
“Experimental Study on strength properties of concrete by partial
replacement of cement with sugarcane bagasse ash and coarse aggregate with
coconut shell by the addition of steel fibers”
Submitted in partial fulfillment of the completion of VI semester of
BACHELOR OF ENGINEERING
In
CIVIL ENGINEERING

Submitted by
RAKSHITHA K(1SI23CV413)
NIKHITHA U B(1SI23CV410)
YASHODEEP K(1SI22CV047)

under the guidance of

Dr Siddesha H
Associate Professor,
SIT, Tumkur
DEPARTMENT OF CIVIL ENGINEERING
2024-2025
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Course Outcomes

After successful completion of major project, graduates will be able to

CO1: To identify a problem through literature survey and knowledge of

contemporary engineering technology
CO2: To consolidate the literature search to identify issues/gaps and formulate
the engineering problem
CO3: To prepare project schedule for the identified design methodology and
engage in budget analysis, and share responsibility for every member in the
team
CO4: To provide sustainable engineering solution considering health, safety,
legal, cultural is- sues and also demonstrate concern for environment
CO5: To identify and apply the mathematical concepts, science concepts,
engineering and management concepts necessary to implement the identified
engineering problem
CO6: To select the engineering tools/components required to implement the
proposed solution for the identified engineering problem
CO7: To analyze, design, and implement optimal design solution, interpret
results of experiments and draw valid conclusion
CO8: To demonstrate effective written communication through the project
report, the one- page poster presentation, and preparation of the video about
the project and the four pages IEEE/Springer/ paper format of the work
CO9: To engage in effective oral communication through power point
presentation and demonstration of the project work
CO10: To demonstrate compliance to the prescribed standards/ safety norms
and abide by the norms of professional ethics
CO11: To perform in the team, contribute to the team and
mentor/lead the team Attainment level: - 1: Slight (low) 2:
Moderate (medium) 3: Substantial (high)

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Knowledge and Attitude Profile (WK) WK1: A systematic, theory-

based understanding of the natural sciences applicable to the discipline and
awareness of relevant social sciences.
WK2: Conceptually-based mathematics, numerical analysis, data analysis,
statistics and for- mal aspects of computer and information science to support
detailed analysis and modelling applicable to the discipline.
WK3: A systematic, theory-based formulation of engineering fundamentals
required in the engineering discipline.
WK4: Engineering specialist knowledge that provides theoretical frameworks and
bodies of knowledge for the accepted practice areas in the engineering discipline; much
is at the forefront of the discipline.

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PSO1 PSO2
CO-1
CO-2 2
CO-3
CO-4 2
CO-5
CO-6
CO-7 2 2
CO-8
CO-9 2
CO-10
CO-11 2
Average

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WK5: Knowledge, including efficient resource use, environmental impacts,

whole-life cost, re- use of resources, net zero carbon, and similar concepts, that
supports engineering design and operations in a practice area.
WK6: Knowledge of engineering practice (technology) in the practice areas in
the engineering discipline.
WK7: Knowledge of the role of engineering in society and identified issues in
engineering practice in the discipline, such as the professional responsibility of
an engineer to public safety and sustainable development.
WK8: Engagement with selected knowledge in the current research literature
of the discipline, awareness of the power of critical thinking and creative
approaches to evaluate emerging issues.
WK9: Ethics, inclusive behavior and conduct. Knowledge of professional
ethics, responsibilities, and norms of engineering practice. Awareness of
the need for diversity by reason of ethnicity, gender, age, physical ability
etc. with mutual understanding and respect, and of inclusive attitudes.
Program Outcomes (POs)
PO1: Engineering Knowledge: Apply knowledge of mathematics, natural
science, computing, engineering fundamentals and an engineering
specialization as specified in WK1 to WK4 respectively to develop to the
solution of complex engineering problems
PO2: Problem Analysis: Identify, formulate, review research literature and

analyze complex engineering problems reaching substantiated conclusions

with consideration for sustainable development (WK1 to WK4)
PO3: Design/Development of Solutions: Design creative solutions for complex
engineering problems and design/develop systems/components/processes to meet
identified needs with con- sideration for the public health and safety, whole-life
cost, net zero carbon, culture, society and environment as required (WK5)

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PO4: Conduct Investigations of Complex Problems: Conduct investigations of

complex engineering problems using research-based knowledge including
design of experiments, modelling, analysis interpretation of data to provide
valid conclusions (WK8)
PO5: Engineering Tool Usage: Create, select and apply appropriate techniques,
resources and modern engineering IT tools, including prediction and
modelling recognizing their limitations to solve complex engineering
problems (WK2 and WK6)
PO6: The Engineer and The World: Analyze and evaluate societal and
environmental aspects while solving complex engineering problems for its
impact on sustainability with reference to economy, health, safety, legal
framework, culture and environment. (WK1, WK5, and WK7) PO7: Ethics:
Apply ethical principles and commit to professional ethics, human values,
diversity and inclusion; adhere to national international laws. (WK9)
PO8: Individual and Collaborative Team work: Function effectively as an
individual, and as a member or leader in diverse/multi-disciplinary teams
PO9: Communication: Communicate effectively and inclusively within the
engineering com- munity and society at large, such as being able to
comprehend and write effective reports and design documentation, make
effective presentations considering cultural, language, and learning differences
PO10: Project Management and Finance: Apply knowledge and understanding
of engineering management principles and economic decision-making and apply
these to one’s own work, as a member and leader in a team, and to manage
projects and in multidisciplinary environments
PO11: Life-Long Learning: Recognize the need for, and have the
preparation and ability for
i) independent and life-long learning ii) adaptability to new and emerging
technologies and iii) critical thinking in the broadest context of technological
change. (WK8)

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ABSTRACT
At this time, researchers from all corners of the world are focusing the attention
on developing strategies that may make use of waste products from either
industrial or agricultural operations as a supply of raw materials for the
construction sector. The production of these wastes may have originated in either
the industrial or agricultural sectors. The majority of researchers are working
toward the goal of producing high-strength concrete by continuing to increase the
compressive strength of concrete through the use of a variety of techniques, such
as the incorporation of fiber reinforcement into the concrete mixture and the
addition of specific admixtures, which may include super plasticizers. This will
allow for the production of concrete with a greater capacity to withstand loads.
The majority of researchers are concentrating
their efforts on developing more cost-effective strategies for increasing the
strength of concrete by incorporating philosophical considerations into the design
process and making use of contemporary techniques. This is due to the fact that
the expense of these methods cannot be weighed against the benefits
that they provide. Ash from sugarcane bagasse and broken coconut shells may be
used as a substitute for fine aggregate and coarse aggregate, respectively, as one
such approach that may be used. During the process of refining sugar, a variety
of fibrous waste products are produced, in addition to ethanol vapour. One of
these waste products is bagasse, which originates from sugar cane. Ash produced
from bagasse mostly consists of aluminium ions and silica in its composition. The
viability of using ash derived from sugarcane bagasse as a partial replacement for
fine aggregate and coconut shells as a source of coarse material was investigated
through a series of controlled laboratory experiments.
The feasibility of using waste coconut shell (CS) as a partial replacement for
conventional coarse aggregates (CA) and waste sugarcane bagasse ash (SCBA)
as a partial substitute for cement. Concrete mixes incorporating 0%,5%, 10%,
15%, and 20% of CS and SCBA aim to promote sustainability by reducing

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dependence on traditional cement and coarse aggregates. However, at 20%

replacement, there is a reduction in compressive strength, split tensile strength,
and flexural strength.

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CONTENTS

Abstract 05

1. Introduction 08

1.1 Objective of the report 09

1.2 Organization of the report 09

2. Literature survey 11

2.1 literature review 16

3. Methodology 18

3.1 Collection of materials 19

3.2 Casting and curing of concrete 24

3.3 Tests conducted 27

3.4 Applications 28

4. Project schedule 31

Conclusion 32

Reference 33

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CHAPTER 01
INTRODUCTION
Production of cement is a key ingredient in concrete, presents a major
environmental concern due to its significant contribution to greenhouse gas
emissions. Cement production is responsible for over 7% of global carbon dioxide
emissions, making it one of the largest industrial contributors to these emissions.
This high environmental cost arises primarily from the energy- intensive
calcination process, during which limestone (calcium carbonate) is heated to
produce lime (calcium oxide), releasing carbon dioxide in the process. Burning
fossil fuels in cement factories releases more carbon dioxide, making cement
production worse for the environment. With the pressing need to combat climate
change, developing alternative materials to reduce the carbon footprint of concrete
has become a critical area of research and innovation. One effective approach to
minimizing concrete’s environmental impact is the use of supplementary
cementitious materials (SCMs). SCMs are materials that, when combined
with Portland cement, improve the properties of concrete while reducing the
amount of cement required. Common SCMs include fly ash, slag, and silica fume,
which are industrial by-products that enhance concrete’s workability, density,
compressive strength, and durability. The use of SCMs not only decreases the
demand for cement, but also helps repurpose industrial waste, addressing both
carbon emissions and waste management issues. Coconut shell offers an
innovative alternative material, particularly in tropical regions where coconuts
are abundantly produced. The global coconut industry generates approximately
fifty billion coconuts annually, resulting in a substantial volume of coconut shells.
Unfortunately, around 85% of these shells are discarded as waste and end up in
landfills, contributing to environmental pollution. When coconut shells
decompose, they release methane, a greenhouse gas far more potent than carbon
and produce leachate that can contaminate soil and water sources as shown

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Figure 1.2.
To address these issues, cement was replaced with SCBA, and coarse aggregate
was replaced with coconut shells in concrete mixes as shown in Figure 1.2.
However, this replacement led to reduced strength in certain proportions of SCBA
and CS. To overcome this limitation and improve the mechanical properties of
the concrete, were added. This addition significantly enhanced the compressive
and tensile strength, resulting in a more durable and sustainable material. The
approach not only reduces the environmental footprint of concrete but also
provides an efficient use of agricultural waste while minimizing landfill pollution.

Fig 1.1: sugarcane bagasse ash Fig 1.2: coconut shell

1.2 OBJECTIVE OF THE REPORT

To investigate the strength properties of sugarcane bagasse ash as partial
replacement with cement and coconut shell as partial replacement with coarse
aggregate in concrete by addition of steel fibres.

1.3 ORGANIZATION OF THE REPORT

The report is organized into several key sections to ensure a comprehensive
presentation of the research conducted. Chapter 1 introduces the project, outlines
its objectives, explains the organization of the report and defines the problem

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statement, establishing the study’s purpose and context. Chapter 2 presents a

detailed literature survey, summarizing prior research and identifying gaps that
this study addresses. Chapter 3, title of the chapter, provides comprehensive
description about the figures, equations, tables. Chapter 4 objectives. Chapter5
the methodology, provides a comprehensive description of material collection,
concrete mix design, specimen preparation, and testing procedures for fresh and
hardened concrete. Chapter 6 expected outcomes conclude the report by
summarizing key findings, emphasizing the benefits of using sugarcane bagasse
ash and coconut shell in concrete and proposing directions for future research,
such as exploring other materials and advanced techniques. Finally, the report
concludes with a bibliography, ensuring proper citation of references discusses
the results, systematically presenting findings on workability, compressive
strength, split tensile strength, and flexural strength, supported by tables and
graphs for clarity.

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CHAPTER 02
LITERATURE SURVEY
This chapter includes the various literature survey carried out related to the
project.
Scarlett allende et.al. [1] (2023), the environmental impact of cement production
and the potential for using sugarcane bagasse ash (SCBA) as a sustainable
alternative. It highlights the increasing global demand for concrete and the
associated depletion of natural resources and greenhouse gas emissions. The
review discusses previous studies on using industrial and agricultural waste as
partial cement replacements, emphasizing the need for efficient conversion
methods. It explores biochar and SCBA's pozzolanic properties, microwave-
assisted pyrolysis as a sustainable conversion method, and comparative studies
on various biomass sources for cementitious applications. The review also
addresses the impact of SCBA characteristics, including chemical composition,
surface area, and hydration properties, on concrete performance.

Rangitha b tangadai et.al. [2] (2021), the growing need for sustainable
alternatives in concrete production due to the depletion of natural resources and
increasing costs of conventional aggregates. It references previous studies where
agricultural and industrial by-products such as bagasse ash, rice husk ash,
sawdust, and fly ash have been used as alternatives for fine aggregates. Similarly,
the review mentions the use of materials like sugarcane waste, crumb rubber, and
industrial waste (e.g., foundry sand, copper slag) as substitutes for coarse
aggregates. The paper emphasizes the environmental benefits of using coconut
shell, which is widely available in tropical regions and poses disposal challenges.
It discusses how coconut shell has been investigated in previous studies as a
lightweight aggregate, showing potential in improving concrete properties while
reducing waste. The literature review supports the research objective of

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determining the optimal percentage of CS replacement in concrete to balance

strength and sustainability.

Mohit varma and Kunwar Ragavendra singh [3] et.al. (2024), the use of
sugarcane bagasse ash (SCBA) and sugarcane fiber (SF) as sustainable
alternatives in concrete production. It highlights the environmental concerns
related to cement production, such as high energy consumption and greenhouse
gas emissions, leading to increased research into alternative materials. The review
discusses the pozzolanic properties of SCBA, which contains high amounts of
silica, alumina, and ferric oxide, making it a viable partial cement replacement.
Previous studies have shown that incorporating SCBA enhances the mechanical
and durability properties of concrete, reducing waste disposal issues and
contributing to sustainable construction. Additionally, the review addresses the
effects of various supplementary cementitious materials, including fly ash, silica
fume, and palm oil fuel ash, which have been studied for their contributions to
concrete strength and durability. It notes that limited research exists on the
combined use of SCBA as a cement replacement and sugarcane fiber as an
additive in concrete. The paper builds on prior research by investigating optimal
SCBA replacement levels (5%, 10%, and 15%) and sugarcane fiber additions
(0.5% and 1%) to determine their impact on compressive and split tensile
strength, as well as acid and sulfate resistance. The study aims to contribute to the
development of eco-friendly concrete while improving its mechanical
performance.

Naraindas bheel et.al. [4] (2021), the environmental concerns associated with
conventional concrete, particularly high CO2 emissions from cement production
and the depletion of natural resources like river sand. It explores the potential of
agricultural waste materials, specifically coconut shell ash (CSA) and sugarcane
bagasse ash (SCBA), as sustainable alternatives in concrete. Key findings from
past studies indicate that CSA, due to its pozzolanic properties, can partially

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replace cement, enhancing mechanical strength up to an optimal level. Similarly,

SCBA has been used as a fine aggregate replacement, improving strength but
increasing water demand. Previous research has primarily examined these
materials separately, but their combined effect on concrete properties remains
underexplored. This study aims to fill that gap by analyzing workability,
mechanical properties, and embodied carbon in concrete containing both CSA
and SCBA.

Senthil p Mathew et.al. [5] (2020), the use of coconut shells as a partial
replacement for coarse aggregate in concrete. It discusses the sustainability
benefits, including waste reduction and eco-friendliness, while maintaining
structural integrity. Various studies indicate that replacing conventional
aggregates with coconut shells lowers thermal conductivity, enhances insulation,
and improves energy efficiency in buildings. Prior research also examines
mechanical properties, durability, and bond strength, confirming that coconut
shell aggregate concrete (CSAC) can be classified as lightweight structural
concrete. The review concludes that CSAC is a promising material for thermal
insulating applications in sustainable construction.

Kavishan sasthasara ravatunga et.al. [6] – ( 2023), examines the environmental

impact of cement production and explores the potential of coconut shell ash
(CSA) as a sustainable supplementary cementitious material (SCM). It discusses
commonly used SCMs such as fly ash, silica fume, slag, and metakaolin,
highlighting their benefits and limitations. The review notes that CSA contains
essential cementitious properties and has been studied for its effects on concrete
workability, density, and compressive strength. However, past research has
primarily focused on lower replacement levels (10-15%) without thoroughly
analyzing environmental impact. This study aims to address these gaps by
determining the optimal concrete mix design using CSA while balancing
structural performance and sustainability.

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Muhammad jahanzaib khalil et.al. [7] (2020), explores the use of sugarcane
bagasse ash (SCBA) as a sustainable partial replacement for cement in concrete.
It examines previous research on SCBA’s chemical and physical properties,
highlighting its high silica content, which enhances pozzolanic activity. The
review discusses SCBA’s impact on fresh and hardened concrete properties,
including workability, compressive strength, modulus of elasticity, and
durability. Studies suggest optimal SCBA replacement levels between 5-20%,
improving strength and resistance to chloride penetration while reducing cement
consumption and environmental impact. The review supports SCBA as a viable
material for sustainable concrete production.

Safiki ainomungisha et.al. [8] (2024), the use of sugarcane bagasse ash (SCBA)
as a supplementary cementitious material (SCM) to reduce clinker consumption
in cement production. It highlights the environmental impact of traditional
cement manufacturing, which contributes significantly to global CO₂ emissions.
Various studies have explored alternative binders such as fly ash, slag, and
volcanic ash, with SCBA emerging as a promising option due to its high
pozzolanic content. However, the effectiveness of SCBA varies based on regional
factors like soil composition and processing methods. The review identifies a
research gap in optimizing SCBA-clinker blends, particularly in East Africa, and
aims to investigate how different SCBA pre-treatment methods impact cement
properties.

Siddartha bhoj et.al. [9] (2018), the use of coconut shells as a sustainable
alternative to conventional coarse aggregates in concrete. It highlights the
increasing demand for concrete and the depletion of natural resources,
emphasizing the need for eco-friendly alternatives. The review explores previous
research on coconut shell aggregates, noting their high lignin content, resistance
to weathering, and potential for improving concrete workability. Studies indicate
that replacing up to 15% of coarse aggregates with coconut shells maintains

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acceptable strength and durability. Additionally, microstructural analysis shows

that coconut shells aid in bonding and C-S-H gel formation, supporting their use
in sustainable concrete production.

S janani p kulanthaival et.al. [10] (2022), the use of coconut shell (CS) as a
sustainable alternative to conventional coarse aggregates in concrete. It highlights
CS’s impact on mechanical properties, durability, and microstructure. Studies
show that CS concrete has lower density, good impact resistance, and comparable
strength when combined with pozzolanic materials. However, challenges like
reduced workability and strength need further research. The review supports CS
as a viable eco-friendly material for lightweight concrete applications.

Rajwindar singh and Mahesh patil et.al. [11] (2023), the use of sugarcane
bagasse ash (SCBA) as a partial replacement for natural fine aggregate (NFA) in
concrete production. It examines previous research on various agro-industrial
byproducts, such as rice husk ash, coconut shell ash, and corncob ash, used in
concrete to enhance mechanical and durability properties. The review highlights
the benefits and limitations of SCBA in improving compressive strength, split
tensile strength, and durability while also noting potential drawbacks such as
reduced workability and strength at higher replacement levels. Additionally, the
study discusses the use of machine learning (ML) models in construction
research, particularly for predicting concrete properties. Various ML techniques,
such as artificial neural networks, support vector machines, and decision trees,
have been used to predict compressive strength with high accuracy. The literature
review emphasizes the need for more studies on SCBA-based concrete,
particularly integrating experimental approaches with artificial intelligence for
enhanced predictive analysis.

Nengsen wu et.al. [12] (2021), the use of Sugar Cane Bagasse Ash (SCBA) as
a cement replacement in Ultra- High -Performance Concrete (UHPC). It highlights

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the environmental benefits of using SCBA, an agricultural byproduct, to reduce

cement consumption, energy use, and CO₂ emissions. The review explores
previous studies on biomass ash materials like rice husk ash and palm oil fuel ash,
which have been successfully used in concrete. It notes that SCBA has good
pozzolanic properties and has been used in various concrete types, including
conventional, high-performance, and self-compacting concrete. However, its
application in UHPC is relatively unexplored. The paper aims to bridge this gap
by investigating SCBA's effects on UHPC properties such as strength,
workability, and shrinkage.

SUMMARY OF LITERATURE SURVEY

Researchers in India have explored the potential of using waste coconut shells
and sugarcane bagasse ash SCBA in concrete to enhance sustainability and reduce
environmental impact. Coconut shells, used as partial replacements for
conventional coarse aggregates, resulting lighter concrete and initially lower
compressive strength; however, this reduction dimensions over time. Studies on
lightweight self-consolidating concrete with coconut shell aggregates revealed
improved permeability and durability. reinforced concrete further enhanced
compressive, flexural, and tensile strength. Using up to 20% coconut shells in
M20 grade concrete maintained workability and strength while effectively
addressing agricultural waste. Additionally, replacing up to 20% of cement with
SCBA achieved target compressive strengths and reduced the environmental
footprint by over 15%, demonstrating the feasibility of these materials for
sustainable construction.

PROBLEM STATEMENT
Increasing environmental concerns and the need for sustainable construction
materials, the disposal of waste coconut shells presents a significant challenge in
India. The project addresses this issue by exploring the feasibility of utilizing

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sugarcane bagasse ash as a partial replacement for cement and coconut shell as a
substitute for coarse aggregate in concrete production.

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CHAPTER 03
METHODOLOGY
The process begins with gathering essential materials, including coconut shells,
cement, coarse aggregate, and fine aggregate. These materials are then mixed in
specified proportions to formulate various concrete designs. The fresh concrete’s
properties, such as consistency and flow, are assessed using standard tests to
ensure quality.
Workability is evaluated through tests like the slump test. Subsequently, the
concrete is poured into moulds to create test specimens, which are cured under
controlled conditions to achieve desired strength characteristics. Finally, the
specimens undergo compressive and split tensile strength tests at predetermined
intervals to evaluate their performance as shown in Figure 3.1.
These are the steps are conducted:

Fig 3.1: Flowchart of Methodology

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3.1 Collection of Materials

The collection of materials involves the following key components:
• Cement
Ordinary Portland Cement of 53 grade was used, meeting the specifications
outlined in IS: 12269-2013. The properties of the cement are presented in Table
3.1 while Figure3.1 illustrates the type of cement utilized, categorized as Ordinary
Portland Cement 53grade. Cement is the primary binding agent in concrete,
essential for ensuring the quality of the final product. Ordinary Portland Cement
(OPC) of 53 grade, compliant with IS: 12269-2013, was utilized. The initial and
final setting times of the cement fall within30 and 280minutes, respectively,
ensuring optimal workability and timely hardening. Additionally, the cement’s
soundness and consistency adhere to the specified standards.

Figure 3.1: Ordinary Portland Cement 53 grade

Table 3.1: Properties of cement

Tests Results
Specific gravity 3.15
Normal consistency 25%
Initial setting time 30 minutes
Final setting time 280 minutes

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• Sugarcane Bagasse Ash

Sugarcane bagasse contains approximately 60–70% volatile matter and moisture,

which are largely eliminated during the carbonization process. For this study,
freshly collected sugarcane bagasse, an agricultural byproduct, was used to
produce Sugarcane Bagasse Ash (SCBA). The bagasse was thoroughly cleaned
and sun-dried for 8 hours to reduce its moisture content, and then subjected to a
controlled carbonization process at 700°C for 2 hours in a muffle furnace. The
combustion time was carefully regulated to minimize harmful emissions and
reduce environmental impact. After carbonization, the weight of the sugarcane
bagasse was reduced by nearly 36.7%. The specific gravity of the resulting SCBA
was measured to be 2.13. The ash was ground using a ball mill to produce fine
particles, with the grinding process taking 7 minutes per kilogram of SCBA. The
powdered ash was then passed through a 90 µ sieve to ensure uniform particle
size.

Figure 3.2: Sugarcane Bagasse Ash

• Coconut Shell
Locally available CS were collected and dried for 20 days before being crushed
with a rammer to obtain aggregates of the desired small sizes, as shown in Figure
3.4. Coconut shells with a maximum size of 20 mm were sieved from the
crushed material and used for the study.

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• Aggregates
20mm downsize coarse aggregate is used as the maximum size of coarse
aggregates. M sand complying with Zone II according to IS 383-2016 was used
as fine aggregate. Figure 3.6 and 3.7 shows the 20mm downsize coarse aggregates
and M-Sand respectively. The maximum size of coarse aggregates used in this
study is 20mm downsize. The fine aggregate utilized is M-sand, which meets the
specifications of Zone II as per IS 383-2016.The properties of both the M-sand
and the coarse aggregate are provided in Table 3.2.

Figure 3.5: 20 mm Downsize Coarse Aggregates

Figure 3.6: M-Sand

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Table 3.2: Basic tests on aggregates

Constituents Tests Results

Fine aggregate Specific gravity 2.58
Fineness modulus 2.65
Grading zone II
Water absorption 2.59%
Coarse aggregate Specific gravity 2.73
Water absorption 0.4%

• Water

Water is crucial in concrete for hydration, strength, workability, curing,

and temperature control. It helps cement form calcium silicate hydrates
(C-S-H) for durability and allows for proper mixing. The right water-to-
cement ratio ensures consistency, prevents cracks during curing, and
maintains uniformity in the mix Proper water control is essential to avoid
weakening or improper hydration.

• Concrete Mix Proportion

The concrete mix design for M20 grade concrete was carried out in accordance
with IS 10262-2019 guidelines. A constant binder content of 448 kg/m* and a
water-cement ratio of 0.45 were maintained throughout the process. The volume
of aggregates was determined by assuming 1% entrapped air in the fresh concrete
mix, and the aggregate weight was calculated based on the volume of aggregates
per cubic meter of concrete. Various mixes were prepared to assess the
compressive, split tensile, and flexural strengths of concrete incorporating
Crushed Stone and Crushed Stone Aggregate.

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For 1m^3 0f cement CEMENT SCBA M SAND CA CS

0% 448.05333 0 652.52809 958.1829 0
5% 425.65067 22.40266667 652.52809 910.2737 47.909144

10% 403.248 44.80533333 652.52809 862.3646 95.818288

15% 380.84533 67.208 652.52809 814.4555 143.72743

20% 358.44267 89.61066667 652.52809 766.5463 191.63658

25% 336.04 112.0133333 652.52809 718.6372 239.54572

• Specimen Preparation

The coarse aggregate (20 mm down), fine aggregate (4.75 mm down),

cement mix were combined in a 300 kg electric revolving drum mixer.
Initially, all the components were blended to create a uniform dry mix.
Once the dry mix was obtained, water was added, and the pan mixer
was rotated to ensure thorough mixing of all the ingredients. Figure3.7
shows the pan mixer used in the experiment. Following the mixing
process, a slump test was conducted, and the concrete was then poured
into moulds for casting.

Figure 3.7: Pan mixer

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3.2 Casting and Curing of Concrete

The method outlined in IS 1199 (Part V): 2018 for mixing and
curing was followed to cast all concrete specimens. After mixing
the concrete and conducting the slump test, the concrete was poured
into cubes and cylinders to assess the properties of the hardened concrete.
The moulds were oiled before pouring the concrete. To measure the
compressive strength at 7 and 28 days, cubes measuring 150mm X
150mm X 150mm were cast, as shown in Figure 3.8. Additionally, the
concrete was tested for split tensile strength using cylinders with a
diameter of 150mm and a height of 300mm, as depicted in Figure
3.9.150mm X 150mm X 750mm were casted for the flexural strength
test and cured for 7 and 28 days for the beams as shown in Figure
3.10.

Figure 3.8: Casting of concrete cubes

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Figure 3.9: Casting of concrete Cylinders

Fig 3.10 Casting of concrete Beams

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Fig 3.11 Curing of moulds

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3.3 Tests conducted:

1. Specific gravity of cement = 3.13

2. Specific gravity of fine aggregate = 2.52

3. Specific gravity of coarse aggregate and water absorption = 2.51

Water absorption = 0.39~ 0.4%

➢ Test conducted on Cube:

For 7 Days:

• Compression test (for 3 cubes)

1. 312*1000/22500 = 13.86 mpa

2. 290*1000/22500 = 12.88 mpa

3. 325*1000*22500 = 14.44 mpa

➢ Test conducted on cylinder:

• Split tensile strength test

1. 238.5*1000/17671.45 = 13.49 mpa

2. 290*1000/17671.45 = 16.41 mpa

3. 262.2*1000/17671.45 = 14.88 mpa

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3.4 Applications
1. Concrete Cube moulds

Concrete cube moulds are essential tools in the field of civil engineering,
particularly in the testing and evaluation of concrete's compressive strength.
These moulds are typically made from cast iron, steel, or durable plastic and
are used to shape fresh concrete into standard cube specimens, most
commonly of size 150 mm × 150 mm × 150 mm. Once the concrete is poured
into the moulds and compacted, the cubes are cured for specific time periods,
usually 7, 14, or 28 days. After curing, the cubes are tested using a
compression testing machine to determine their compressive strength, which
is a critical property for structural design and construction quality assurance.

The use of concrete cube moulds plays a vital role in ensuring that the concrete
mix used in construction meets the required specifications and strength grades.
They are widely used in both site and laboratory conditions to monitor and
control the quality of concrete during various phases of a construction project.
In addition to strength testing, cube moulds are also employed in validating
concrete mix designs before large-scale construction begins. This ensures that
the chosen proportions of cement, aggregates, water, and admixtures result in
a durable and workable mix.

Beyond construction practice, concrete cube moulds have significant

applications in academic institutions and research laboratories. They are used
in experiments that investigate the effects of different additives, curing
conditions, or replacement materials such as fly ash, silica fume, and coconut
shell ash on the properties of concrete. Furthermore, they assist in durability
studies, where concrete’s resistance to environmental factors like water
penetration, chemical attack, or freeze-thaw cycles is evaluated. Overall,
concrete cube moulds are a standardized and indispensable part of concrete
testing, supporting both practical construction needs and scientific

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advancements.

2. Cylinder moulds

Concrete cylinder moulds are cylindrical forms used to cast concrete samples
primarily for determining compressive strength and split tensile strength.
The most commonly used dimensions are 150 mm in diameter and 300 mm in
height. These moulds are widely used in countries like the United States,
where cylinder specimens are preferred over cubes due to their more uniform
stress distribution during testing. The moulds are typically made of metal or
heavy-duty plastic to maintain shape and dimensional accuracy.

Once filled and compacted, the cylindrical concrete specimens are cured for a
specified duration, often 7, 14, or 28 days, similar to cubes. After curing, the
specimens undergo compressive testing in a machine that applies load axially
to the cylinder. This provides a measure of the concrete’s compressive
strength, which is vital for structural safety and integrity. Cylinders are also
used for split tensile strength testing, where the specimen is loaded along its
side to induce tensile stress across the vertical diameter, helping assess
concrete's resistance to cracking.

Cylinder moulds are crucial in the validation of concrete mix designs and are
often used in combination with cube and beam specimens for a comprehensive
understanding of a concrete mix's mechanical properties. In research and
academic settings, they are used to evaluate the effects of additives,
temperature variations, curing methods, and chemical exposures on concrete
behaviour. Their simple shape also makes them ideal for advanced studies,
including ultrasonic pulse velocity testing and internal microstructure
analysis.

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3. Beams

Concrete beam moulds are used to cast prismatic concrete specimens, usually
with standard dimensions such as 100 mm × 100 mm × 500 mm or 150 mm ×
150 mm × 700 mm, depending on the testing requirements. These moulds are
made from steel or rigid plastic to retain dimensional accuracy during casting
and handling. The primary purpose of beam moulds is to evaluate the flexural
strength of concrete, which is a critical property in the design of pavements,
slabs, and other structural elements subjected to bending forces.

In practice, freshly mixed concrete is filled into the beam moulds in layers,
properly compacted, and then cured under controlled conditions. After the
curing period, the concrete beams are tested using a flexural testing machine
to measure their resistance to bending or fracture. This test helps engineers
understand how well the concrete can withstand tensile stress across its span,
which is important for elements that experience bending moments in service.

Concrete beam moulds are also used in research to study the performance of
different concrete mixes, including those modified with fibres, admixtures, or
waste materials. They are commonly used in road and pavement research,
where flexural strength plays a more prominent role than compressive
strength. Additionally, beam specimens allow for the assessment of crack
formation and propagation under loading, contributing to durability
evaluations and structural performance predictions.

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CHAPTER 04
PROJECT SCHEDULE

Project Schedule
22-Feb-2504-Mar-2514-Mar-2524-Mar-2503-Apr-2513-Apr-2523-Apr-2503-May-2513-May-2523-May-2502-Jun-2512-Jun-25

Literature survey 01-Apr-25

Materials procurment 11-Apr-25

Basic test on materials 15-Apr-25

casting of moulds 03-May-25

curing process 06-May-25

Test on mould 03-Jun-25

Basic test on Materials

Test on mould curing process casting of moulds Literature survey
materials procurment
Start date 03-Jun-25 06-May-25 03-May-25 15-Apr-25 11-Apr-25 01-Apr-25

Start date

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CONCLUSION

The casting of concrete cubes, cylinders, and beams is a crucial procedure in

evaluating the mechanical properties of concrete, such as compressive, tensile,
and flexural strength. Proper mixing, accurate proportioning, and careful
placement of concrete in the moulds ensure the reliability of the test results.
Adequate compaction and timely curing play a vital role in achieving desired
strength. These standard specimens help assess the quality and durability of
concrete used in construction, ensuring safety and performance in structural
applications.

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REFERENCES
1. Scarlett allende et.al. “Sugarcane Bagasse-Derived Carbon for
Partial Replacement of Cementitious Material in Concrete”
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