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International Journal of Innovative and Emerging Research in Engineering
Volume 2, Issue 2, 2015
70
Available online at www.ijiere.com
International Journal of Innovative and Emerging
Research in Engineering e-ISSN: 2394 – 3343 p-ISSN: 2394 – 5494
“SELF COMPACTING CONCRETE USING
NEUTRALIZED RED MUD”
Manjur A.Shendure1,Mohit Uphade2&Gagan Chajjed3
M.Tech Construction Management and M.B.A. Project & Construction Management, MIT College Of
Management,Pune, Maharashtra, India 1,2,3
[email protected] ,[email protected] ,[email protected]
ABSTRACT
The main aim of the experiment is to study the effect on properties of self compacting concrete using neutralized
red mud. The flow characteristics of self compacting concrete using neutralized red mud is measured from J-ring
test, V-funnel test, U-box test, L- box test, J-Ring test. Also the strength properties of self-compacting concrete
using neutralized red mud like compressive strength and these properties are compared with ordinary concrete
strength and normal self compacting concrete and attempt has been made to study the effect of replacement of
cement with Neutralized Red Mud and performance of concrete using it.
Keywords: Self Compacting Concrete, Neutralized Red Mud, V-funnel, U-box, L- box test
CITATION: (1)“Application of industrial waste in manufacturing of self compacting concrete”, Government College of
Engineering, Karad, (2) Paratibha Aggarwal1
, Rafat Siddique2,*
, Yogesh Aggarwal1
, Surinder M Gupta,”Self-
Compacting Concrete - Procedure for Mix Design”,Leonardo Electronic Journal of Practices and Technologies, Issue 12,
Page No. 15-24,January-June 2008, (3) Hajime Okamura1 Masahiro Ouchi2,”Self Compacting Concrete”, Journal of
advanced concrete technology Vol.1,No.1,Page No.7,April 2003
I. INTRODUCTION
The development of new technology in the material science is progressing rapidly. In recent years, a lot of research was
carried out throughout the world to improve the performance of concrete in terms of its most important properties, i.e.
strength and durability. The field of concrete technology has seen miraculous changes due to the invention of various
admixtures. The admixtures modify the properties of fresh concrete and offer many advantages to the user. Concrete has
no longer remained a construction material consisting of cement, aggregate, and water only, but has becomes an
engineered custom tailored material with several new constituents like micro silica, colloidal silica and many other
binders, fillers and pozzolanic materials to meet the specific needs of construction industry.
A. Self Compacting Concrete
The development of specifying a concrete according to its performance and requirements, rather than the constituents and
ingredients have opened innumerable opportunities for producers of concrete and users to design concrete to suit their
specific requirements. Concrete technology has undergone from macro to micro level study in the enhancement of
strength and durability properties from 1980 onwards. Till 1980 the research study was focused only to flow ability of
concrete, so as to enhance the strength however durability did not draw lot of attention of the concrete technologists. This
type of study has resulted in the development of self compacting concrete (SCC), a much needed revolution in concrete
industry.
One of the most outstanding advances in the concrete technology in the last decade is “self compacting concrete”
(SCC).The concept of Self-compacting was proposed in 1986 by Professor Hajime Okamura. However the prototype was
first developed in 1988 in Japan, by Professor Ozawa at the University of Tokyo. Now, all over the world, a lot of
research is going on, so as to optimize the fluidity of concrete with its strength and durability properties without a
drastically increase in the cost. The first North American conference on design and use of self-consolidation concrete was
organized in November 2002. At present many researchers are working in numerous universities and government R&D
organizations due to benefits of the use of this concrete. A very limited work is reported from India, where the future for
concrete is very bright due to scarcity of skilled man power, non-mechanization of construction industry, abundant
availability of construction materials available at very low cost. Therefore, it can be said that SCC is still quite unknown
to many researchers, builders, ready mix concrete producers, academia etc.
Self-Compacting Concrete is a High Performance Concrete, which distinguishes itself with self-consolidation properties
with high flow ability. At Present self-compacting concrete can be considered as an advanced construction material. In
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structural practices, sometimes, there are inaccessible pockets or zones where concrete cannot be placed, except
availability of small opening through which concrete can be fed. Poking the concrete with instruments such as vibrators
becomes impossible. In such contingencies concrete should flow like a fluid on its self-weight and travel to all
inaccessible zones without segregation. This is where application of SCC makes a lot of sense.
B. Need of SCC?
Now having a look over history of SCC, question arises that what is needed to go for SCC? So, here are some of the
important aspects to go with SCC:
The answer to the problem may be a type of concrete which can get compacted into every corner of form work and gap
between steel, purely by means of its own weight and without the need for compaction. The SCC concept was required to
overcome these difficulties. The SCC concept can be stated as the concrete that meets special performance and
uniformity requirements that cannot always be obtained by using conventional ingredients, normal mixing procedure and
curing practices. The SCC is an engineered material consisting of cement, aggregates, water and admixtures with several
new constituents like colloidal silica, pozzolanic materials, and chemical admixtures to take care of specific
requirements, such as, high-flow ability, compressive strength, high workability, enhanced resistances to chemical or
mechanical stresses, lower permeability, durability, resistance against segregation, and possibility under dense
reinforcement conditions.
The properties, such as, fluidity and high resistance to segregation enables the placement of concrete without
vibrations and with reduced labour, noise and much less wear and tear of equipment. Use of SCC overcomes the problem
of concrete placement in heavily reinforced sections and it helps to shorten construction period. Self-compacting concrete
is growing rapidly, especially in the precast market where its advantages are rapidly understood and utilized. Super
plasticizer enhances deformability and with the reduction of water/powder segregation resistance is increased. High
deformability and high segregation resistance is obtained by limiting the amount of coarse aggregate. However, the high
dosage of super-plasticizer used for reduction of the liquid limit and for better workability, the high powder content as
‘lubricant’ for the coarse aggregates, as well as the use of viscosity-agents to increase the viscosity of the concrete have
to be taken into account.
As the name suggests, it does not require to be vibrated to achieve full compaction. This offers many 2 benefits and
advantages over conventional concrete. SCC has an improved quality of concrete and reduction of on-site repairs, faster
construction times, lower overall costs and facilitation of introduction of automation into concrete construction.
C. Use of Red Mud in Construction
Scientists, engineers and technologists are continuously in search for materials which can be used as substitutes for
conventional materials or which posses such properties that would enable their use for new design and innovations. The
raw materials for making cement and aggregates are essentially limitless since practically all the earth’s crust can be
utilized if associated costs and energy requirements can be compiled with it. This course of action cannot be taken as
there are other constraints that merit the closer examination .Various materials can be used in making concrete. Some of
these are tried with some success while others are in feasible form of using them in concrete making. The form in which
they are used is wide and varied, they may be used as binder material, as partial replacers of Portland cement or directly
as aggregates in their natural or processed states. Due to industrialization there is greater increase in the amount of red
mud which is one of the major solid wastes coming from Bayer process of alumina production. This red mud produced
every day and dumped on the ground causes threat to environment. It causes ground water pollution and land
deterioration. This red mud can be used in construction activity thus reducing the problem of environmental pollution and
reducing the cost of construction and also it may make the concrete high performing from the durability point of view.
The Red mud is the iron rich residue from the digestion of bauxite. It is one of the major solid wastes coming from Bayer
process of alumina production. In general, about 2-4 tones of bauxite is required for production of each tone of alumina
(Al2O3) & about one tone red mud is generated. Since the red mud is generated in bulk it has to be stored in large
confined & impervious ponds, therefore the bauxite refining is gradually encircled by the" storage ponds. At present
about 60 million tones of red mud is generated annually worldwide which is not being disposed or recycled satisfactorily.
In the most common method of dumping that is the impoundment on land in a disked impervious area called ponds. The
mud slurry is pumped to the ponds situated close to the bauxite refinery .The mud accumulates & settles in the pond in
due course of time. In order to reduce alkali pollution through red mud a number of methods using drainage decantation
& special technique such as dry disposal have been developed. Dry disposal is expensive & not yet installed anywhere in
India. However the dry disposal can only conserve the land to a considerable extent, but the conservation of minerals
remains unattempted.
II. OBJECTIVES OF SELF COMPACTINNG CONCRETE USING NEUTRALIZED RED MUD?
This work is carried out to study the properties of neutralized red mud in self compacting concrete, and attempt has been
made to study the effect of replacement of cement with NRM (Neutralized Red Mud) and performance of concrete using
it.
Following are some of the objectives:
Study the properties of self compacting concrete in fresh and hardened state.
Study the effect of neutralized red mud, in replacement of cement used in different proportions on the physical
properties of self-compacting concrete.
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Comparison between the properties of SCC when neutralized red mud is used in different proportions.
By keeping above objectives in mind, the aims of present study were to check the suitability and utilization of NRM as
partial replacement of cement and fly ash in self compacting concrete.
With the above objectives, a comparative study on strength parameters is done against conventional concrete and self
compacting concrete to study the behavior of SCC with NRM.
The experimental test carried out was as follows:
The Flow properties of SCC was measured by taking tests like Slump Flow Test, U-Box Test, L-Box Test, J-Ring
Test, V-Funnel Test.
With constant water/cement ratio, concrete design mix of M50 grade (SCC) was prepared and was studied for
Compressive strength.
The cement is replaced by 15% NRM by optimization in conventional concrete and hence the 15% NRM in SCC with
varying proportion of fly ash like 30%, 35%, 40%. The Compressive test are done after curing period of 7 days, 28
days and 56 days for the water/binder ratio of 0.4 for concrete mix design of M50 grade (SCC).
For Compressive strength test specimens of size 150mmX150mmX150mm were prepared for every mix and cement
is replaced by 15% NRM and different proportion of Fly ash in SCC. In all concrete mix design Ultra Tech OPC 43
Grade Cement, locally available river sand and coarse aggregate (20mm down size) were used.
III. PROCEDURE OF CONCRETE MIX AND OPTIMIZATION OF NRM
D. Preparation of moulds
The standard cast iron moulds were used for casting of specimen. The standard size of mould 150mm X 150 mm X 150
mm, beam mould 100 mm X 100 mm X 500 mm and Cylinder 100mm dia. & 200 mm height were used. The moulds
were checked for dimension with vernier. The moulds were clean with wire brush and then oiled before casting work.
E. Preparation Of Concrete
Self Compacting Concrete design mix of grade M50 was prepared by trial & Error Method and the mixing of ingredients
was done as per the design. Cement was replaced by various percentage of NRM in conventional concrete for
optimization.
Figure 1.Optimization
F. Casting of Cubes
The specimens were prepared and directly place in moulds. Excess material was removed and the mould was leveled by
using trowel.
G. Curing And Testing Of Specimen
All the casted mould was kept undisturbed on leveled platform. They were demoulded carefully after 24 hrs immediately
after demoulding the specimen were marked by their respective identification mark/number (ID) and then they were
carefully transfer to the curing tank for water curing. Testing of cubes was carried in compression testing machine of
capacity 2000 KN capacity to determine the compression test of design mix.
CONCERETE MIX DESIGN FOR SELF COMPACTING CONCRETE
Mix design can be defined as the process of selecting suitable ingredients of concrete and pining their relative
proportions with the object of producing concrete of certain minimum strength and durability as economically as
possible. One of the ultimate aims of studying the various properties of the materials of concrete is to enable a concrete
technologist to design a concrete mix for a particular strength and durability. Following are the some methods available
for concrete design mix.
Indian Road Congress, IRC 44 Method
High Strength Concrete Mix Design
ACI Committee 211 Method
Indian Standard Recommended Method, IS 10262-2007
Trial-Error Method
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Out of the above methods, some of them are not very widely used because of some difficulties or drawbacks in the
procedure for arriving at the satisfactory proportions. The ACI Committee 211 method and Indian Standard
Recommended methods are commonly used for concrete design.
Hence for this project work Indian Standard Recommended Method, IS 10262 and Trial-Error method was adopted to
calculate the proportions of ingredients of concrete.
TRIALS OF M 50 GRADE CONCRETE DESIGN MIX ( SELF COMPACTING CONCRETE)
Table 1. Trial Mix Design
Following are the Slump Cone, Slump Flow Test and Compressive Strength Test for Trial Mix design
Slump Cone and Slump Flow Test
Table 2.Slump Cone & Slump Flow Test
Trial Mix Slump Cone Test
(Height mm)
Slump Flow Test
(Dia.mm)
1 220 515
2 230 520
3 270 550
4 210 530
5 220 620
6 230 680
7 280 775
8 270 730
9 200 500
Tri
al M
ix N
o.
Bin
der
Kg
/m3
W/B
Kg
/m3
Cem
ent
Fly
Ash
San
d
Ag
gre
gat
e K
g/m
3
Wat
er
Ad
mix
ture
s
(Of
Bin
der
)
1 480 0.50 1.00 0.2 2.289 2.04 0.5
1% Pozolith55R
2 520 0.40 1.00 0.3 2.683 1.716 0.5
1% Pozolith
55R
3 480 0.4 1.00 0.538 3.32 2.20 0.4
1% Pozolith 55R,
0.2% Glenium
Stream 2
4 480 0.4 1.00 0.538 3.32 2.20 0.4
1% Pozolith 55R,
0.4% Glenium
Stream 2
5 480 0.4 1.00 0.538 3.32 2.20 0.4
1% Pozolith 55R,
0.1% Glenium
Stream 2
6 480 0.4 1.00 0.538 3.32 2.20 0.4
1.5% Pozolith 55R,
0.2% Glenium
Stream 2
7 480 0.4 1.00 0.538 3.32 2.20 0.4
1 % STP
8 480 0.4 1.00 0.538 3.32 2.20 0.4
0.7 % STP
9 480 0.4 1.00 0.538 3.32 2.20 0.4
1% Pozolith 55R
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Figure 2.Slump Cone & Slump Flow Test
3 -Days Compressive Strength in N/mm2
Table 3.Compressive Strengths
Trial Mix Compressive Strength N/mm2
1 11.41
2 10.22
3 10.82
4 9.87
5 8.85
6 9.27
7 12.52
8 10.89
9 7.038
Figure 3.Compressive Test
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On the basis of above Slump Cone Test & Slump Flow Test(Table11& Graph No.2,Graph No.4) and 3 Days
Compressive Test Result(Table12,Graph No.3 Graph No.5),we Finalized Trial Mix No. 7 as Self Compacting Concrete
Mix Design
Concrete Design Mix (M 50 Grade)
Table 4.Final M 50 Grade Mix Design
Quantities
of
Ingredient
Required
for
Casting 1
cube
1 : 0.538 : 3.32: 2.20: 0.4
Table 5. Material quantities required for one cube
1. Cement = 1.1029 Kg
2. Fly Ash = 0.593 Kg
3. Sand = 3.66 Kg
4. Aggregate = 2.426 Kg
1 Grade of concrete : M-50
2 Cement : Ultra Tech (OPC 43Grade)
3 Target Strength[fc]
=
=
=
fck + (1.65 x S)
50 + (1.65 x 5)
58.25 N/mm2
4 Specific Gravity
Cement :
3.1
Sand :
2.85
Aggregate : 3.05
Fly Ash : 2.2
5 Binder : 480 Kg/m3
6 Cement : 312 Kg/m3
7 Fly Ash : 168 Kg/m3
8 Water content : 192 Kg/m3 (0.615)
7 Sand Content[fa] : 1036.88 Kg/m3
8 Coarse Aggregate [ca] : 689.04 Kg/m3
9 Final Mix Proportion
Cement
(Kg/m3)
Fly Ash
(Kg/m3)
Fine Aggregate
(Kg/m3)
Coarse Aggregate
(Kg/m3)
Water
(Kg/m3)
312 168 689.04 1036.88
192
10 Concrete Design Mix Ratio
1 0.538 3.32 2.20 0.615
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5. Water = 0.678 Kg
6. Chemical = 0.01696 Kg
V. RESULT ANALYSIS
A. Fresh Property
For 15 % Neutralized Red Mud and 35% Fly Ash
Table 6.Fresh Property of Concrete
SLUMP TEST Slump Flow (mm) 635
T-50 Sec 7.2
J-Ring Test
Slump Flow (mm) 575
Ht. Inside J-Ring(mm) 270
Ht. Outside J-Ring (mm) 280
L-Box Test
T-20 Sec. 6.32
T-40 Sec. 13.4
H2/H1 0.915
U-Box Test H1-H2 (mm) 9
V-Funnel Test T0 Sec. 8.21
T5 min. Sec. 11.45
For 15 % Neutralized Red Mud and 30% Fly Ash
Table 7.Fresh Property of Concrete
SLUMP TEST Slump Flow (mm) 690
T-50 Sec 8.2
J-Ring Test
Slum Flow (mm) 640
Ht. Inside J-Ring (mm) 266
Ht. Outside J-Ring (mm) 275
L-Box Test
T-20 Sec. 5.90
T-40 Sec. 13.10
H2/H1 1.116
U-Box Test H1-H2 (mm) 16
V-Funnel Test T0 Sec. 7.53
T5 min. Sec. 12.95
For 15 % Neutralized Red Mud and 40% Fly Ash
Table 8.Fresh Property of Concrete
SLUMP TEST
Slump Flow (mm) 650
T-50 Sec 8.05
J-Ring Test
Slum Flow (mm) 595
Ht. Inside J-Ring (mm) 272
Ht. Outside J-Ring (mm) 289
L-Box Test
T-20 Sec. 7.2
T-40 Sec. 14.23
H2/H1 0.975
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U-Box Test H1-H2 (mm) 13
V-Funnel Test
T0 Sec. 9.05
T5 min. Sec. 13.25
B. Hardened Property
7 Days Compressive Strength
Table 9.Hardened property
Cube
ID Length Breadth
Area Of Cube
in mm2
Compressive
Strength in N/
mm2
Average
Compressive
Strength in N/
mm2
A
150 147 22050 19.29
18.92 150 147 22050 18.59
150 150 22500 18.88
B
152 150 22800 17.10
17.14 153 150 22950 17.21
150 150 22500 17.11
C
150 149 22350 15.65
15.16 150 149 22350 14.54
150 148 22200 15.31
A=SCC with 35% Fly Ash & 15% NRM
B= SCC with 30% Fly Ash & 15% NRM
C= SCC with 40% Fly Ash & 15% NRM
Figure 4. 7 days Compressive Test
28 Days Compressive Strength
Table 10.Hardened Properties
Cube
ID Length Breadth
Area Of Cube
in mm2
Compressive
Strength in N/
mm2
Average
Compressive
Strength in N/
mm2
A
150 150 22500 30.44
30.22 150 150 22500 30.22
150 150 22500 30.00
B
150 150 22500 28.00
27.62 150 150 22500 27.77
150 150 22500 27.11
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C
150 150 22500 24.88
25.36 150 148 22200 25.67
150 150 22500 25.55
A=SCC with 35% Fly Ash & 15% NRM
B= SCC with 30% Fly Ash & 15% NRM
C= SCC with 40% Fly Ash & 15% NRM
Figure 5. 28 days Compressive Test
56 Days Compressive Strength
Table 11.Hardened property
Cube
ID Length Breadth
Area Of Cube
in mm2
Compressive
Strength in N/
mm2
Average
Compressive
Strength in N/
mm2
A
150 150 22500 60.00
60.07 150 150 22500 58.66
150 150 22500 61.55
B
150 150 22500 53.33
53.18 150 150 22500 52.44
150 150 22500 53.77
C
150 150 22500 49.33
48.73 150 148 22500 50.66
150 150 22500 46.22
A=SCC with 35% Fly Ash & 15% NRM
B= SCC with 30% Fly Ash & 15% NRM
C= SCC with 40% Fly Ash & 15% NRM
Figure 6. 58 days Compressive Test
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Figure 7.Compressive Test Comparison
7 Days Compressive Strength
Table 12.7 Days Compressive Test
Cube
ID Length Breadth
Area Of Cube
in mm2
Compressive
Strength in N/
mm2
Average
Compressive
Strength in N/
mm2
1
150 150 22500 35.55
35.03 150 150 22500 34.66
150 150 22500 34.88
2
150 150 22500 39.55
39.923 150 150 22500 40.00
150 150 22500 40.22
1=SCC with 35% Fly Ash & 0 % NRM
2= Conventional Concrete
Figure 8. 7 Compressive Strength
28 Days Compressive Strength
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Table 13.28 Days Compressive Strength
Cube
ID Length Breadth
Area Of Cube
in mm2
Compressive
Strength in N/
mm2
Average
Compressive
Strength in N/
mm2
1
150 150 22500 56.00
55.403 150 150 22500 55.55
150 150 22500 54.66
2
150 150 22500 60.00
59.85 150 150 22500 59.11
150 150 22500 60.44
1=SCC with 35% Fly Ash & 0 % NRM
2= Conventional Concrete
Figure 9. 28 Days Compressive Strength
56 Days Compressive Strength
Table 14.56 Days Compressive Test
Cube
ID Length Breadth
Area Of Cube
in mm2
Compressive
Strength in N/
mm2
Average
Compressive
Strength in N/
mm2
1
150 150 22500 73.22
74.03 150 150 22500 74.22
150 150 22500 74.66
2
150 150 22500 80.44
79.85 150 150 22500 79.11
150 150 22500 80.00
1=SCC with 35% Fly Ash & 0 % NRM
2= Conventional Concrete
Figure 10. 56 Days Compressive Test
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VI. CONCLUSION After testing of Self compacting concrete with 15% NRM and variation in fly ash as 30%, 35%, 40% , Self Compacting
Concrete with 35% fly ash & 0% NRM and Conventional Concrete, we found following results:-
WITH RESPECT TO STRENGTH
By using 35% fly ash and 15% neutralized red mud gives more compressive strength than 30% fly ash and 15%
neutralized red mud & 40% fly ash and 15% neutralized red mud.
Self compacting concrete with 35% fly ash and 0% NRM gives minimum strength against conventional concrete but
it is achieved is targeted strength.
Self compacting concrete using 15% neutralized red mud (35% fly ash) gives minimum strength against self
compacting concrete with 35% fly ash and 0% NRM but it is achieved is targeted strength.
Finally we concluded that, using 35% Fly Ash +15% NRM gives optimum for properties of self compacting concrete
(SCC) & also Compressive Strength.
VII. PHOTOS
.
Figure 11.Dry mix of neutralized red mud self compacting concrete
Figure 12.Slump Cone Test
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Figure 13. U-Box Test
VII. REFERENCE
[1] Bouziani Tayeb*1,, Benmounah Abdelbaki1, Bederina Madani2 and Lamara Mohamed2, “Effect of Marble
Powder on the Properties of Self-Compacting Sand Concrete”:-The Open Construction and Building
Technology Journal, Page No 25-29,2011.
[2] Farukh Farrokhi, “Self compacting concrete”, Institute of beton technology-technical university of graz-austria
[3] Hajime Okamura1 Masahiro Ouchi2,”Self Compacting Concrete”, Journal of advanced concrete technology
Vol.1,No.1, Page No.7,April 2003.
[4] I Papayianni1,E.Anastasiou,”1Development of self compacting concrete by using high volume of calcareous fly
ash”, World of coal ash(WOCA),conformance abstract, May 9-12,2011 in Denver, Co USA.
[5] Indian Road Congress, IRC 44 Method.
[6] Indian Standard Recommended Method IS 10262-2007.
[7] M.L.Gambhir, “Concrete Technology, published by The McGraw-Hill Companies, New Delhi.
[8] Mohammed Sonebi,“Medium strength self-compacting concrete containing fly ash”, Advanced Concrete and
Masonry Centre, University of Paisley, Paisley PA1 2BE, Scotland, UK.
[9] M.S.Shetty, “Concrete Technology Theory & Practice,published by S.Chand & Company,Ram Nagar,New
Delhi.
[10] Nan Sua*, Kung-Chung Hsub, His-Wen Chaic,, “A simple mix design method for self-compacting concrete”,
Cement and Concrete Research ,Page No.1-9, 2001.
[11] Prakash Parasivamurthy,Veena Jawali,B.V.Kiran kumar,Study of Self Compacting High Volume Fly Ash
Concrete using silica fume fly ash, World of coal ash(WOCA),conformance abstract, May 9-12,2011 in Denver,
Co USA.
[12] Paratibha Aggarwal1, Rafat Siddique2,*, Yogesh Aggarwal1, Surinder M Gupta,”Self-Compacting Concrete -
Procedure for Mix Design”, Leonardo Electronic Journal of Practices and Technologies, Issue 12, Page No. 15-
24,January-June 2008.
[13] Suraj N. Shah, Shweta S. Sutar, Archana S. Shelake, “Application of industrial waste in manufacturing of self
compacting concrete”,Government College of Engineering, Karad.
[14] V.Boel, K.Audenaert, G.De Schutter, “Transport properties of self compacting concrete with limestone filler or
fly ash” ,Materials and Structures, 2007.