Study on Strength of Hybrid Mortar Synthesis with Epoxy Resin, Fly Ash and Quarry Dust Under Extreme Conditions

Blend and characterization of Bisphenol-A diglycidyl ether based thermosetting polymer mortar comprising an epoxy resin, Fly ash and Quarry dust are presented here for the strength study. The specimens have been prepared by means of an innovative process in Extreme conditions of commercial epoxy resin, Fly ash and Quarry dust based paste. In this way, thermosetting based hybrid mortars characterized by a different contents of normalized Fly ash and Quarry dust by a homogeneous distribution of the resin have been attained. Once hardened, these new composite materials show improved compressive strength and toughness in respect to both the Fly ash and Rock sand pastes since the Resin provides a more cohesive microstructure, with a reduced number of micro cracks. The micro structural characterization allows pointing out the presence of an Interfacial Transition Zone similar to that observed in cement based mortars. A correlation between micro-structural features and mechanical properties of the mortar has also been studied in Extreme conditions.


INTRODUCTION
The use of fly ash in mortar is desirable because of benefits such as useful disposal of a by-product, increased workability, sulphate resistance, resistance to alkali-silica reaction and decreased permeability. Quarry dust is a by-product obtained from the crushing process of granite in the quarry. The concurrent use of the two by-products will lead to a range of economic and environmental benefits. Quarry dust has been proposed as an alternative to river sand that gives additional benefit to mortar. Quarry dust is known to increase the strength of mortar over mortar made with equal quantities of river sand. When examining the above qualities of fly ash and quarry dust, it becomes apparent that if both are used together, the loss in early strength due to on and the loss of workability due to the one may be partially negated by the improvement in workability caused by the inclusion of the other. Epoxy is a term used to denote both the basic components epoxy resins, as well as a colloquial name for the epoxide functional group. Epoxy resins, also known as poly-epoxides are a class of reactive pre epoxide groups. Epoxy resins may be reacte catalytic homopolymerization, or with a wide range of co amines, acids (and acid anhydrides), phenols, and alcohols. These co referred to as hardeners or curatives, and the cross curing. Reaction of poly-epoxides with themselves or with polyfunctional hardeners forms a thermosetting polymer, often with high mechanical properties, temperature and chemical resistance. Epoxy has a wide range of applications, including metal coatings, use in electronics / electrical components, high tension electrical insulators, fiber materials and structural adhesives.

2.1.Physical properties, SEM and EDS report of Quarry dust:
Physical properties of Quarry dust are determined in the laboratory and reported in Table1. strength of mortar over mortar made with equal quantities of river sand. When examining the above qualities of fly ash and quarry dust, it becomes apparent that if both are used together, the loss in early strength due to one may be improved by the gain in strength due to the other, and the loss of workability due to the one may be partially negated by the improvement in workability caused by the inclusion of the other. Epoxy is a term used to denote both the basic components and the cured end products of epoxy resins, as well as a colloquial name for the epoxide functional group. Epoxy resins, epoxides are a class of reactive pre-polymers and polymers which contain epoxide groups. Epoxy resins may be reacted (cross-linked) either with themselves through catalytic homopolymerization, or with a wide range of co-reactants including polyfunctional amines, acids (and acid anhydrides), phenols, and alcohols. These co-reactants are often curatives, and the cross-linking reaction is commonly referred to as epoxides with themselves or with polyfunctional hardeners forms a thermosetting polymer, often with high mechanical properties, temperature and chemical ce. Epoxy has a wide range of applications, including metal coatings, use in electronics / electrical components, high tension electrical insulators, fiber-reinforced plastic materials and structural adhesives.

SEM and EDS report of Quarry dust:
Physical properties of Quarry dust are determined in the laboratory and reported in Table 1. Physical properties of Quarry dust  strength of mortar over mortar made with equal quantities of river sand. When examining the above qualities of fly ash and quarry dust, it becomes apparent that if both are used together, e may be improved by the gain in strength due to the other, and the loss of workability due to the one may be partially negated by the improvement in and the cured end products of epoxy resins, as well as a colloquial name for the epoxide functional group. Epoxy resins, polymers and polymers which contain linked) either with themselves through reactants including polyfunctional reactants are often linking reaction is commonly referred to as epoxides with themselves or with polyfunctional hardeners forms a thermosetting polymer, often with high mechanical properties, temperature and chemical ce. Epoxy has a wide range of applications, including metal coatings, use in reinforced plastic SEM analysis of Quarry dust dust particle are relatively angular in shape and also sharp edge pin headed faces found all around the particle surface at the stage of microstructural investigation up to 100 to 50, micron scale view. EDS analysis report of Quarry dust which reveals us from the above Figure 1.2, that the quarry dust sample having the following chemical compositions like Al 20%, Si-(SiO 2 ) is about 70%, Potassium(K) is about 10% are available.

2.2.Chemical properties, SEM and EDS report of Fly ash:
The fly ash was procured from National Thermal Power Corporation (NTPC) in Visakhapatnam. The properties of Fly ash are as follows. Fineness of test Fly ash: Specific gravity of test Fly ash: 2.55, The chemical properties of fly ash are given in Table2.   Figure 2.1, that the Fly Ash particle is of spherical in shape, its particle size is varying between 2 following are the particle sizes noted from above pictures at the stage of micro structural investigation in between 50 to 20 5.998, 6.54, 7.449, 7.998, 8.421, 9.814, 10.602, 12.47, 15.929 SEM analysis of Quarry dust which reveals us from the above Figure 1.1, that the Quarry dust particle are relatively angular in shape and also sharp edge pin headed faces found all around the particle surface at the stage of microstructural investigation up to 100 to 50,  Figure 2.1, that the Fly Ash particle is of spherical in shape, its particle size is varying between 2-11-micron meter. The particle sizes noted from above pictures at the stage of micro structural investigation in between 50 to 20-micron scale view is, 3 which reveals us from the above Figure 1.1, that the Quarry dust particle are relatively angular in shape and also sharp edge pin headed faces found all around the particle surface at the stage of microstructural investigation up to 100 to 50, EDS analysis report of Quarry dust which reveals us from the above Figure 1

2.3.Mix ratio, SEM and EDS report of Epoxy resin (Hardened):
Araldite AW 106 resin/Hardener HV 953U epoxy adhesive is a multi-purpose, viscous material that is suitable for bonding a variety of materials including metal, ceramic and wood. Araldite AW 106 resin/Hardener HV 953U epoxy adhesive cures at temperatures from 68ºF (20ºC) to 356ºF (180ºC) with no release of volatile constituents.

RESULTS AND DISCUSSIONS
Various combinations of mixes are tried and the same are shown in Table 4. The compressive strength values fo curing period at a temperature of 100ºC for all mixes are shown in Tables 5  relative comparison

RESULTS AND DISCUSSIONS
Various combinations of mixes are tried and the same are shown in Table 4. The compressive strength values for 24 hrs curing period at a temperature of 50ºC and 3 hrs curing period at a temperature of 100ºC for all mixes are shown in Tables 5.1     . Average compressive strength of all variations in MPa at the age of 24 hrs. (50ºC).  Table 6. Average compressive strength of cylindrical specimens in M Variation 5 (Fly ash with 30% Epoxy) S1 S2 S3 (According to Table 5   Inference of Figure 10.1: SEM analysis of Fly Ash with 30% Epoxy on its weight of (Variation-5), it reveals us that how compactly Fly Ash particle is bonded with epoxy and forming a massive structure with no micro level crack and no voids in it from above figure at the stage of microstructural investigation in between 10 to 5, micron scale view. From above figure, it reveals that the fly ash particles having size 1.782 and 2.684, micron meter having bond length is less than 1.0, micron meter length and also reveals that the fly ash particles having size 2.853 and 3.30, micron meter having bond length 0.691, micron meter length which supports the high strength mortar results.  Inference of Figure 11.1: SEM analysis of Variation -4, with 30% Epoxy on its weight it reveals us that how closely quarry dust particles are linked and bonded with epoxy to forming a massive structure and also observed the different shapes and sizes of quarry dust particles. From above figure 11.1 (b), it reveals that some micro cracks of size 0.99. 1.04 and 1.088, micron meter length and micro voids are observed at the stage of microstructural investigation at 10, micron scale view which causes the lesser strength for mix variation-4, compare to mix variation-5.

CONCLUSIONS
From the above study the following conclusions are drawn.
1. According to Indian standards from figures 4 & 7, variations 2, 3, 4, and 5 with 20% of epoxy are shows relatively same strength with quarry dust and fly ash. 4. According to ASTM standards from Table 6 and 7 in variation-5, fly ash with 30% of epoxy is shows more compressive strength i.e. more than 100 N/mm 2 . 5. SEM analysis also reveals that, Variation-5 means fly ash with 30% epoxy is shows more massive (with no micro cracks and voids) structure that supports more compressive and tough materials.