PSI - Issue 70

Siddesh K N et al. / Procedia Structural Integrity 70 (2025) 231–238

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cast and cured. Additionally, RC beams (700 mm × 150 mm × 150 mm) were cast with 0% – 5% cement replacement by aluminum dross and cured for 28 days. The beams were tested under two-point bending using a 400 kN universal testing machine (UTM) (Fig. 3). A 5 kg incremental load was applied, and dial gauges recorded displacement. The beams, simply supported with a 600 mm effective span, were tested until failure, with load vs. displacement plotted for each specimen.

Fig. 3. Two-point bending test set up

2. Finite Element modelling Geometry for the finite element modelling were drawn using AutoCAD Software. Static Structural nonlinear analysis was carried out to study the shear behaviour of RC beams with and without aluminium dross. SOLID65 element was used for concrete and REINF265 element was used for mild steel bars, stirrups and mechanical steel stiches. SOLID65 and REINF265 element and comprises of eight nodes having three degrees of freedom at each node: translations in the nodal x, y, and z directions. SOLID65 element is capable of cracking in tension and crushing in compression. REINF264 element has plasticity, stress stiffening, creep, large deflection, and large strain capabilities Meshing size of 2 mm was employed for concrete layer and Mesh size of 1 mm was employed for Reinforcement. The geometry of the model is as shown in Fig. 4.

Fig. 4. Geometry model of reinforced concrete beam

3. Results and Discussion The study involved casting 42 concrete cubes (150 mm × 150 mm × 150 mm) with aluminum dross replacing cement at 0% to 30% in 5% increments. Each replacement level had 6 cubes, tested at 7 and 28 days. Based on compressive strength results, the optimum replacement range was identified. Subsequently, 12 beams (2 per mix) with 0% – 5% Al Dross were cast and tested after 28 days to evaluate flexural performance.