International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-9, Issue-3, January-2020 1 Published By: Blue Eyes Intelligence Engineering & Sciences Publication Retrieval Number: A4116119119 /2020©BEIESP DOI: 10.35940/ijitee.A4116.019320 Concrete Mix Design by Partial Surrogation of Conventional Aggregates with Fabrigated Aggregates Shital Mohanrao Bhandare, J.S.R Prasad, Venu Malagavelli Abstract: Since the invention of concrete in the early 18 th century, there has been a constant rise in efforts to increase the productivity of this material so that it becomes more economical. The economy of concrete also depends on the use of products that are abundantly available in the near vicinity, at the least processing costs. One such material is the coal ash. It is an unavoidable residual yield of the thermal power plants which are the major electricity producers in India. The 120 power plants produce 120-150 million tons of fly ash per year. The disposal of this fly ash is a complicated task as it takes a very large space to dump, also this causes air pollution and harmful health conditions when inhaled. Many attempts have been made to utilize this material in the recent past. One such attempt is the use of fly ash in concrete. Is has been found that fly ash can be used as an important constituent of concrete in the form of aggregates. The market for fly ash aggregate has one of the most intriguing opportunity for business owners as use of fly ash has no seasonal problems, as it could be stored for a very long time in open surroundings without the risk of losses, environmental hazard or freeze-thaw condition complications. The use of fly ash aggregates is a very good application for the disposal of fly ash. Keywords: Fly ash aggregate, Fly ash, Compressive strength, split tensile test, flexural strength I. INTRODUCTION Concrete is produced with mixing materials such as cement, aggregates and water in predetermined proportions. These materials are all either directly obtained from nature or processed before using after obtaining from nature. There has been an effort to replace some of these materials by recycled cheaper materials which would not only reduce the carbon foot print but also solve the waste disposal problem to some extent. One such material is the fly ash that is a residual of thermal electricity generation. In general, the disposal of Fly Ash is done in both dry and wet condition. The constituents of it are Arsenic, Chromium, Nickel, Cadmium, Lead, Antimony, etc. which possesses respiratory problems, cancers, blood iron decrement and skin irritations [1]. Another major concern is that Indian coals produce high amounts of ash comparatively which has already increased thee problem [2]. Revised Manuscript Received on January 5, 2020 Shital Mohanrao Bhandare, M.Tech in structural engineering in department of Civil Engineering Institute of Aeronautical Engineering, Dundigal Hyderabad. Dr. J S R Prasad, professor, Department, Institute of Aeronautical Engineering, Hyderabad. Venu Malagavelli, Department of Civil Engineering, Institute of Aeronautical Engineering, Dundigal, Hyderabad. The main problem of concrete with only fly ash is that it has a strength at early stage but on the advantage side of fly ash is that compressive strength is improved as a result the sulfate durability increases and also the resistance to sulphates [3]. The artificial aggregate production in our country didn’t get much response from the investors even though research has been done in recent past by many on the topic. The reason behind this maybe the relatively high cost of production, natural resources shortage, and energy curing process of artificial aggregates [4]. The fly ash aggregate’s prominent advantage is that it could be stored for any amount of time and it is quite cheap and easy to manufacture as compared to its artificial counterparts. II. METHODOLOGY The concrete was tested and a base line for the tests such as Compressive concrete strength, Split tensile and Flexural strength of concrete was done replacing the coarse aggregates with 0% of fly ash aggregate to 50% fly ash aggregate with an interval of 10% between consecutive mixtures. In all 162 cubes were casted from which 54 were cubes of dimensions 150*150*150mm 3 which were used for testing compressive strength of concrete. For the split tensile strength 54 cylinders were casted of dimensions 300mm in height and 150mm in diameter. Flexural strength was tested using 54 prisms of dimensions 100*100*700mm 3 . For testing the workability the tests namely, slump cone test, compaction factor test and vee bee test were done. Casting and curing of test specimens The sizes of standard cubes [150mm x 150mmx 150mm], Standard prisms [100mm x 100mm x700mm] and standard cylinders [150mm diameter x300mm height] were made. Batching: In batching process, concrete mix ingredients are processed either by mass or by volume and and then added to the mixture. Usually batching is considered by volume but now mass mix is regarded as more accurate and also is preferred for accurate mixes. Batching when done correctly affects workability by reducing the bleeding and segregation in the mix. It also provides a smooth surface of the concrete. It helps in speedy construction and decreases the wastage of material. Hence, batching is considered as an essential step while preparing concrete mix. Mixing of concrete: Measured quantities of coarse aggregate, fine aggregate and cement were spread out over an impervious concrete floor. Fly ash aggregates were added randomly while mixing the concrete. The mixture was rolled over and over until uniformity of color was achieved the time of mixing was between 10 15 minutes.