1

Chapter I
I ntroduction

2

CONCRETE MIX DESIGN BY IS CODE METHOD USING SUPER PLASTICIZER
WITH LOCALLY AVAILABLE MATERIALS (GRADE- M20)
Ingredient of mixes-
The selection of right kind of ingredients having properties which help to
achieve desirable properties of concrete is of utmost importance:-
The ingredients are:-
Cement.
Coarse aggregate.
Fine aggregate.
Superplasticizer.
Water.
Testing of cement: -
fineness test
Specific gravity

Testing of coarse aggregate: -
Specific gravity.
Water absorption test.
Fineness test

Testing of fine aggregate: -
Fineness test.
Water absorption test.
Specific gravity test.

After testing all the materials, the properties of different ingredients
are obtained and after that mixing of these ingredients is done with super plasticizer. Before
casting the cube the slump test is done on this wet mix and then cubes are made. After 24 hours
cubes are taken for curing. Now compressive strength of cubes are obtained after 7 days, 14 days
and 28 days of curing.
3







Chapter II
Principles of mix design
4

2. Principles of mix design:-

2.1. The Principles of Proportioning:


The fundamental object in proportioning concrete or mortar mixes is
the production of a durable material of requisite strength, water tightness, and other essential
properties at minimum cost. To achieve these objectives, careful attention must be given to the
selection of cement, aggregate, and water to the following considerations:

1. The mix must be workable so that it can be placed and finished without undue labour.
2. Since cement is the most costly ingredient in the mix, the proportion used should be as small
as is consistent with the attainment of desired properties.

Within wide limits, experiments have shown:

(a) The strength and degree of water tightness of mixes, having like constituent materials,
density, and workability, increase with the cement content.

(b) With the cement content, materials, and workability all constant, the strength and degree of
water tightness increase with the density of the mix.

(c) For usual methods of placement, the strength and degree of water tightness of well-cured
concrete and mortar are greatest when the mix is plastic (has a slump of approximately 50 mm).
Drier mixes, although frequently as strong, are likely to be porous unless compacted by
pneumatic rammers or electrically driven vibrators. Increasing the water content beyond that
required for plasticity causes the strength to decrease rapidly.

(d) Concrete with 47%, by volume, entrained air made by using an air-entraining cement or by
adding air-entraining admixtures is more resistant to freezing and thawing action and also to
scaling due to the use of salt for ice removal than concrete made with regular cement and without
air-entraining admixtures.

In addition to the above, the following statements appear to be justified by the results of
experience and tests:

(e) To proportion concrete for the maximum resistance to fire, a porous non-combustible
aggregate of high specific heat together with cement sufficient to provide the requisite strength
should be thoroughly mixed and placed with as little ramming as possible to produce a porous
concrete.
5


(f) In proportioning concrete or mortar which is to be subjected to freezing temperatures shortly
after placement, a minimum amount of water and a quick-setting cement should be used.

(g) Concrete for road construction should be made from a carefully graded, hard tough aggregate
bound together with as small a proportion of rich mortar as is consistent with the required
workability, strength, and imperviousness. In locations where resistance to freezing and thawing
is required, the concrete should have 36 per cent of entrained air.
The principal methods used in scientific
proportioning of mixes are based upon relationships between properties and ratio of cement to
voids in the mix, or on the relationship between properties and the ratio of water to cement in the
mix.


2.2. Design Requirements:
Before the engineer can begin to design a concrete mix the following
information from the site of work is required:
(i) Grade of concrete: The grade M 20, denotes characteristic strength, f
ck
of 20 N/mm
2
,
respectively, and standard deviation based on the degree of control to be exercised on site.

(ii) Type of cement: The grade of Ordinary Portland Cement (OPC) such as 33, 43, or 53 grade.
Portland Pozzolana Cement (PPC) to relevant IS specifications.

(iii) Type and size of aggregate: Natural sand, crushed stone, gravel etc. conforming to IS:383
1970, quoting the source of supply.

(iv) Nominal maximum size aggregate (MSA): 40 mm, 20 mm, 10 mm, as per IS:3831970.

(v) Maximum/minimum cement content (kg/m3): This is required for durability/considerations.

(vi) Type of mixing and curing water: Whether fresh potable water, seawater, ground water is to
be used.

(vii) Maximum free water-cement ratio by weight: This is required for considerations of strength
and/or durability for different exposures and to meet appearance and other requirements.

(viii) Degree of workability of concrete: This is dependent on placing and compaction
conditions.

6


(ix) Air content: This is inclusive of entrained air.

(x) Type of admixture used- These days concrete is being used for wide varieties of purpose to
make it suitable in different conditions. In these condition ordinary concrete may fail to exhibit
the required quality performance or durability. In such cases, admixture is used to modify the
properties of ordinary concrete so as to make it more suitable for any situation.
Types of Admixtures are-
Plasticizers .
Superplasticizers
Retarders and Retarding plasticizers.
Accelerators and Accelerating plasticizers.
Air entraining admixture.
Pozzolanic or Mineral admixtures.
Damp-proofing and Waterproofing Admixtures.
Gas forming Admixtures.


(xi) Maximum/ minimum density of concrete.

(xii) Maximum/minimum temperature of fresh concrete.
7







Chapter II I
I ngredients of mix design
8

3. Ingredients of mix design:-

Concrete is essentially a mixture of cement, water, coarse and fine aggregates which consolidates
into a hard mass due to chemical reaction between cement and water. Each of the four
constituents has a specific function. Besides most optimum use of ingredients, the selection of
right kind of ingredients having properties which help to achieve desirable properties of concrete
is of utmost importance. A brief discussion about the ingredients follows.

3.1. Cement:-
The cement used should have a minimum compressive strength at different ages
according to the relevant IS specificationIS:2691987 (33 grade OPC), IS: 81121982 (43
grade OPC), IS:122691987 (53 grade OPC), IS:122301988 (Sulphate resisting cement),
IS:1489-1976 (Portland
Puzzolana cement), IS:4551976 (Portland slag cement). All types of Portland cements are
interchangeable for mix design, and the most commonly used ones are OPC, PPC, PSC, and
SRC.
After water is added to the cement hydration occurs and continues
as long as the relative humidity in the pores is above 85 per cent and sufficient water is available
for the chemical
reactions. On an average, 1 g of cement requires 0.253 g of water for complete hydration. As
hydration proceeds, the ingress of water by diffusion through the deposit of hydration products
around the original cement grain becomes more and more difficult, and the rate of hydration
continuously decreases. In mature paste, the particles of calcium-silicate hydrates form an
interlocking network which is a gel having a specific surface of about 200 m2/g. This gel is
poorly crystalline, almost amorphous, and appears as randomly oriented layers of thin sheets or
buckled ribbon. The gel is the heart of the concrete and is a porous mass. The interstitial spaces
in the gel are called gel pores. The strength giving properties and phenomena, such as creep
and shrinkage are due to the porous structure of the gel, and the strength is due to the bond
afforded by the enormous surface area.

3.2. Aggregate:-
The size of the aggregate, particle shape, color, surface texture, density
(heavyweight or lightweight), impurities, all of which have an influence on the durability of
concrete, should conform to IS: 3831970.
During the process of hydration the products of hydration completely
surround and bind together the aggregate particles in a solid hardened mass. Aggregates
constitute nearly 7075 percent of the total volume of concrete.


9

The strength of concrete is governed by the weakest element, be it the cement paste, the
aggregate or the interface of the aggregate-cement paste. Strong aggregates are also more sound
and durable in aggressive environments. The strength at the aggregate mortar interface is perhaps
more critical, hence the shape, size and texture of the coarse aggregate is important. The
aggregate should be clean, hard, strong, and durable, free from chemicals or coatings of clay or
other fine material that can affect the bond with the cement paste.

3.3. Water:-
Water is required primarily for hydration of cement and to give fluidity to the
plastic mass. Water should be clean and free from impurities. The permissible limits for solids in
mixing and curing water as specified in IS:4562000 are: potable water.

3.4. Admixtures:-
Based on the properties admixture imparts to the concrete, a selection can be
done and the manufactures instructions followed for its method of use. The Bureau of Indian
Standards has also brought out a standard for admixtures, IS: 9103.
Superplasticizers constitute a relatively new category and improved version of
plasticizer. They are chemically different from normal plasticizers. Use of superplasticizers
permits the reduction of water to the extent up to 30% with reducing workability in contrast to
the possible reduction up to 15% in case of plasticizers.
The use of superplasticizer is practiced for production of flowing, self leveling,
self compacting and for the production of high strength and high performance concrete.
The mechanisms of action of superplasticizers are more or less same as
explained earlier in case of ordinary plasticizers.

10






Chapter IV
Test on ingredients

11

4. Test on ingredients:-
4.1. Tests on cement:

4.1.1. Fineness test:
Object- To determine the fineness of cement by dry sieving.
Apparatus- a) Standard balance with 100 gm weighing capacity.
b) IS: 90 micron sieve confirming to IS: 460-1962 and a brush.
Procedure- a) Break down any air-set lumps in the cement sample with hand.
b) Weigh accurately 100 gm of cement and place it on a standard 90 micron sieve.
c) Continuously sieve the sample for 15 minutes.
d) Weigh the residue left after 15 minutes of sieving. This completes the test.
Result-
The percentage weight of residue over the total sample is reported.
Weight of the sample retained on the sieve
% weight of residue =
Total weight of the sample
= (8.47/100) X 100
= 8.47%
Result- The percentage residue is well within the prescribed limit.
Limits- The percentage residue should not exceed 10%.
Precautions- Sieving shall be done by holding the sieve in both hands and gentle wrist motion,
this will involve no danger of spilling the cement, which shall be kept well spread
out on the screen. More or less continuous rotation of the sieve shall be carried out
throughout sieving.


12

4.1.2. Specific gravity test:
Object- To determine the specific gravity of cement using Le Chatelier flask or specific gravity
bottle.
Apparatus- a) Le Chatelier flask or specific gravity bottle- 100 ml capacity.
b) Balance capable of weighing accurately upto 0.1 gm.
Procedure- Weigh a clean and dry Le Chatelier flask or specific gravity bottle with its stopper
(W
1
). Place a sample of cement upto half of the flask (about 50 gm) and weight
with its stopper (W
2
). Add kerosene to cement in flask till it is about half full. Mix
thoroughly with glass rod to remove entrapped air. Continue stirring and add more
kerosene till it is flush with graduated mark. Dry the outside and weigh (W
3
).
Entrapped air may be removed by vacuum pump, if available. Empty the flask,
clean it refills with clean kerosene flush with the graduated mark wipe dry the
outside and weigh (W
4
).
Calculations-
Specific gravity = ( W
2
- W
1
)
(W
2
- W
1
) - (W
3
- W
4
) X 0.79
Where, W
1
= weight of empty flask.
W
2
= weight of flask + cement.
W
3
= weight of flask + cement + kerosene.
W
4
= weight of flask + kerosene.
0.79= specific gravity of kerosene.
Limit- Specific gravity of cement = 3.15 g/cc.
4.2 Tests on aggregate:
4.2.1. Fineness modulus of fine and coarse aggregate:
Object- To obtain the fineness modulus of fine and coarse aggregate samples.
Apparatus- - Sample of fine aggregate.
- Sample of coarse aggregates.
- Digital weighing scale.
13

- Sieve sifter for fine aggregates.
- Sieve sifter for coarse aggregates.
- Various cleaning brushes (point and wire).
Procedure- Part 1: Sieve Analysis of fine aggregate
Step 1: Take 500g sample of fine aggregate (as per IS code provisions, the aggregates
must be completely dry). This is determined by weighing the material on a
digital scale. Also weigh each sieve of the mechanical sifter, and the pan, and
record the weights.

Step 2: Place the aggregate in the top sieve of the well-cleaned mechanical sifter (sieves
used are 4.75mm, 2.36mm, 1.18mm, 900mic, 600mic, 300mic, 150mic,less than
150mic). This apparatus is used for shaking the aggregates (similar to the
principle used in a paint-mixing machine) and sieving them. The mechanical sifter
has a bottom pan and a lid to close the sifter during the test. After placing the lid
on the sifter, agitate the sifter for about 10 minutes.

Step 3: Determine the weight of aggregates that are retained in each of the sieves, by
weighing each of the sieves (along with the retained aggregates), and subtracting
the weight of each sieve. Also record all the weights of aggregates retained in
each of the sieves. To ensure that all materials are collected, clean each sieve
carefully using the proper type of brush. Use the paint brush for the finer sieves,
the copper brush for intermediate sieves and the steel wire brush for the coarse
sieves. Also verify whether the sum of weights of aggregates, retained in all the
sieves, and the bottom pan is equal to the initial weight of the aggregates taken.

Step 4: Tabulate the data and determine the percent retained in each sieve. From these
values calculate the (cumulative) percentage of material that would have been
retained in the sieve if the whole volume of material was to be sifted in that sieve
alone. Then add the percentage of material retained in all the sieves and divide by
100 to get the fineness modulus. Also prepare a column to determine the
cumulative percentage passing through the sieve to plot the fineness modulus
curve.

14


Procedure- Part 2: Sieve Analysis of coarse aggregate

Step 1: Take 5000 grams of coarse aggregates by weighing the material in a digital scale.
Weigh each of the clean sieve, along with the bottom pan, and record their
weights.

Step 2: Place the aggregates in the mechanical sifter (sieve sizes used are 80mm, 40mm,
20mm, 10mm, 4.75mm). This apparatus is used for shaking the material (similar
to the principle of a paint-mixing machine) and sieving it.

Step 3: Determine the aggregates that are retained in each individual sieve, as mentioned
earlier in Part I, and record the data. To ensure that all materials are collected,
use the steel brush to clean each sieve.

Step 4: Tabulate the data and determine the percent retained, and the percentage that
would have been retained in each sieve, if that sieve alone was used to sieve the
whole volume. The fineness modulus is obtained by adding the percentage of
material retained in all the sieves and dividing it by 100.

Calculations are shown in Appendix 6.




15

4.2.2 Specific gravity and water absorption of fine and coarse aggregates:
Object- To determine the specific gravity and water absorption of given sample of coarse
aggregates.
Apparatus-
A balance or scale of capacity not less than 3 kg, readable and accurate to 0.5 g and of
such a type and shape as to permit the basket containing the sample to be suspended from
the beam and the weighed in water.
A well ventilated oven thermostatically controlled to maintain a temperature of 100
o
C to
110
o
C.
A wire basket of not more than 6.3 mm mesh or a perforated container of convenient size.
Two dry soft absorbent cloths each not less than 7545 cm.
A shallow tray of area no less than 650 cm
2
.
Procedure-
A sample of 2000 g of aggregate is used for conducting the test. Aggregate which
have been artificially heated should not normally be used. The sample is thoroughly washed to
remove finer particles and dust, drained and then placed in the wire basket and immersed in
distilled water at a temperature between 22-32C with a cover of at least 50 mm of water above
the top of the basket. Immediately after immersion the interrupted air is removed from the
sample by lifting the basket containing it 25 mm above the base of the tank and allowing it to
drop 25 times at the rate of about one drop per second. The basket and aggregate are kept
completely immersed during the operation and for, 1 period of 24 1/2 hours afterwards. The
basket and the sample are jolted and weighed in water (weight A
1
). These are then removed from
the water and allowed to drain for a few minutes, after which the aggregate are gently emptied
from the basket on to one of the dry clothes. and the empty basket is returned to the water, jolted
25 times and weighed in water (weight A
2
). The aggregate placed on the dry cloth are gently
surface dried with the cloth, and are completely surface dried. The aggregate art' then weighed
(weight B). The aggregate are there after placed in an oven at a temperature of 100-110
o
C and
maintained at this temperature for 24 1/2 hours. It is then removed from the oven, cooled in the
air-tight container and weighed (weight C). The computations are as under-

Specific gravity = C/(B-A)
= 2400/(2410-(2300-800)
= 2.63

Water absorption(percent in dry weight) = ((B-C)/C) X 100
= ((2410-2400)/2400) X 100
= 0.41%

16


Where, A = the weight in g of the saturated aggregate in water (A
1
- A
2
).
B = the weight in g of the saturated surface dry aggregate in air.
C = the weight in g of oven-dried aggregate in air.

Object- To determine the specific gravity and water absorption of given sample of fine
aggregates.
Apparatus-
A balance of capacity not less than 3kg ,readable and accurate to 0.5 gm and of such a
type as to permit the weighing of the vessel containing the aggregate and water .
A well ventilated oven to maintain a temperature of 100C to 110C
Pyconometer of about 1 liter capacity having a metal conical screw top with a 6mm hole
at its apex . The screw top shall be water tight.
A tray of area not less than 32cm.
Filter papers and funnel.
Procedure-
A pycnometer is used for determining specific gravity. A sample about 1000 g
for 10 mm to 4.75 mm or 500 g if finer than 4.75 mm, is placed in the tray and covered with
distilled water at a temperature of 22-32C. Soon after immersion, air entrapped in or bubbles on
the surface of the aggregate are removed by gentle agitation with a rod. The sample is kept
immersed for 24 1/2 hours. The water is then carefully drained from the sample through a filter
paper, any material retained being returned to the sample. The aggregate including any solid
matter retained on the filter paper should be exposed to a gentle current of warm air to evaporate
surface moisture and stirred at frequent intervals to insure uniform drying until no free surface
moisture can be seen and the material just attains a free-running condition. The saturated and
surface dry sample is weighted (weight A). The aggregate is then placed in the pycnometer
which is filled with distilled water. The pycnometer is dried on the outside and weighed (weight
B). The contents of the pycnometer are emptied into the tray. The pycnometer is refilled with
distilled water to same level as before, dried on the outside and weighed (weight C). The water is
17

then carefully drained from the sample by decantation through a filter paper and any material
retained is returned to the sample. The sample is placed in the oven at a temperature of 100 to
110C for 24 1/2 hours, during which period it should be stirred occasionally to facilitate
drying. It is then cooled in the air-tight container and weighed (weight D).

Specific gravity = D/A-(B-C)
= 540/550-(2000-1650)
= 2.70

Water absorption (percent in dry weight) = ((A-D)/D) X 100
= ((550-540)/540) X 100
= 1.85%

Where, A = weight in g of saturated surface-dry sample.
B = weight in g of pycnometer containing sample and filled with distilled
water.
C = weight in g of pycnometer filled with distilled water only.
D = weight in g of oven-dried sample.






18







Chapter V
I S code method of mix design

19

5. IS code method of mix design:-

5.1. Theory:-
This method, now widely used in the country, is recommended for designing
mixes for general types of construction, using the ingredients of concrete normally available. The
design is carried out for a specified compressive strength and workability of concrete using
continuously graded aggregates.

The method can be used for both, reinforced and pre stressed concretes. The
method is not to be used for the design of mixes for flexural strength, or when gap graded(not
continuously graded) aggregates, or when pozzolana, or admixtures are used .The basic
assumption made in the IS method is that the compressive strength of concrete is based on the
water-cement ratio of the concrete mix. Further, for a given type, shape, size and grading of
aggregates, the amount of water determines the workability for normal concretes.

However, there are other factors which also affect the properties of concrete,
for example, the quality and quantity of cement, water and aggregates; method of transporting,
placing, compacting and curing of the concrete. Hence, the proportions arrived at for the mix
design
should be considered only as a basis for a trial, subject to modification in the light of experience
and the actual materials that will be used at site.

In the IS method the general principles and requirements of basic data remain
unchanged. That is, specifying characteristic strength, workability recommendations in terms of
compacting factor Vee-Bee time or slump, type and grade of cement, maximum size of aggregate
used, grading of aggregates according IS: 3831970, and durability requirements in terms of
minimum cement content and maximum water-cement ratio for various exposure conditions.

20

5.2. Factors affecting the choice of mix proportions:-
The various factors affecting the mix design are:
1. Compressive strength:

It is one of the most important properties of concrete and influences many other describable
properties of the hardened concrete. The mean compressive strength required at a specific age,
usually 28 days, determines the nominal water-cement ratio of the mix. The other factor affecting
the strength of concrete at a given age and cured at a prescribed temperature is the degree of
compaction. According to Abrahams law the strength of fully compacted concrete is inversely
proportional to the water-cement ratio.

2. Workability:

The degree of workability required depends on three factors. These are the size of the section to
be concreted, the amount of reinforcement, and the method of compaction to be used. For the
narrow and complicated section with numerous corners or inaccessible parts, the concrete must
have a high workability so that full compaction can be achieved with a reasonable amount of
effort. This also applies to the embedded steel sections. The desired workability depends on the
compacting equipment available at the site.

3. Durability:

The durability of concrete is its resistance to the aggressive environmental conditions. High
strength concrete is generally more durable than low strength concrete. In the situations when the
high strength is not necessary but the conditions of exposure are such that high durability is vital,
the durability requirement will determine the water-cement ratio to be used.

4. Maximum nominal size of aggregate:

In general, larger the maximum size of aggregate, smaller is the cement requirement for a
particular water-cement ratio, because the workability of concrete increases with increase in
maximum size of the aggregate. However, the compressive strength tends to increase with the
decrease in size of aggregate.
IS 456:2000 and IS 1343:1980 recommend that the nominal size of the aggregate should be as
large as possible.



21

5. Grading and type of aggregate:

The grading of aggregate influences the mix proportions for a specified workability and water-
cement ratio. Coarser the grading leaner will be mix which can be used. Very lean mix is not
desirable since it does not contain enough finer material to make the concrete cohesive.
The type of aggregate influences strongly the aggregate-cement ratio for the desired workability
and stipulated water cement ratio. An important feature of a satisfactory aggregate is the
uniformity of the grading which can be achieved by mixing different size fractions.

6. Quality Control:

The degree of control can be estimated statistically by the variations in test results. The variation
in strength results from the variations in the properties of the mix ingredients and lack of control
of accuracy in batching, mixing, placing, curing and testing. The lower the difference between
the mean and minimum strengths of the mix lower will be the cement-content required. The
factor controlling this difference is termed as quality control.

5.3. Mix proportion designations:-

The common method of expressing the proportions of ingredients of a concrete mix is in the
terms of parts or ratios of cement, fine and coarse aggregates. For e.g., a concrete mix of
proportions 1:2:4 means that cement, fine and coarse aggregate are in the ratio 1:2:4 or the mix
contains one part of cement, two parts of fine aggregate and four parts of coarse aggregate. The
proportions are either by volume or by mass. The water-cement ratio is usually expressed in
mass.


5.4. Procedure for mix design:-
The Bureau of Indian standards, recommended a set of procedure for design of concrete mix
mainly based on the work done in national laboratories. The mix design procedures are covered
in IS 10262-82. The method given can be applied for both medium strength and High strength
concrete.
Before we proceed with describing this method step by step, the following short comings
in this method are pointed out. Some of them arisen in view of the revision of IS 456-2000. The
procedure for concrete mix design needs revision and at this point of time (2000AD) a
committee has been formed to look into the matter of mix design.
1. The strength of cement has available in the country today has greatly improve since 1982.
The 28-days strengths of A, B, C, D, E, F, category of cement is to be reviewed.
22

2. The graph connecting, different strength of cement and W/C ratio reestablished.

3. The graph connecting 28-days compressive strength of concrete and W/C is to be
extended up to off 80Mpa, this graph is to be cater for high strength concrete.

4. As per revision of IS 456-2000,the degree of workability is expressed in terms of slump
instead of compacting factor. This result in change of value of estimating approximate
water and sand content for normal concrete up to of 35Mpa and high strength of concrete
above 35Mpa .the table giving adjustment of value in water content and sand percentage
for other than standard conditions, require appropriate change and modification.

5. In view of above and other changes made in the revision of IS 456-2000,the mix design
procedure as recommended in IS 10262-82 is required to the modified to the extent
considered necessary and examples of mix design is work out.
However, in the absence of revision of IS on method of mix design,
the existing method i.e. IS 10262-82 is describe below step by step.
1. Design stipulations:
Characteristics compressive strength Required in the
field at 28 days :20MPa
Maximum size of aggregate :20 mm(angular)
Degree of workability :0.90 compacting factor
Degree of quality control :Good
Type of exposure :Mild




2. Test data for Materials:
Specific gravity of cement :- 3.15
Compressive Strength of cement at 7 days :- Satisfies the requirement of IS: 269-1989
Specific gravity of C.A. :- 2.60
Specific gravity of F.A. :- 2.60
Water absorption:-
1. Coarse aggregate :- 0.50%
2. Fine aggregate :- 1.0%

23

Free(Surface) moisture:- 1. Coarse aggregate :- Nill
2. Fine aggregate :-2.0%
Coarse aggregate
Sieve
Size (mm)
Analysis of coarse
aggregate fractions (%
passing)
Percentage of different
fractions
Remark
I II I II combined
60% 40% 100%

20 100 100 60 40 10 Conforming to grading
Zone III of table 4 IS:
385-1970
10 0 71.20 0 28.5 28.5
4.75 9.40 - - 3.7 3.7
2.36 - - - - -

Fine aggregate
Sieve Size Fine aggregate (% passing) Remarks
4.75mm 100 Conforming to grading
2.36mm 100
1.18mm 93 Zone III of table 4 IS:
600micron 60
300micron 12 385-1970
150micron 2

3. Target mean strength of concrete:
The target mean strength for specified characteristics cube strength is
F
ck
= f
ck
+ ts
F
ck
= 20+1.65x4
F
ck
=26.6 Mpa
Where f
ck
= characteristics compressive strength of 28 days.
S = standard deviation, given in Appendix 2.
t = a statistical value depending on expected proportion of low results (risk factor), given
in Appendix 1
24

4. Selection of Water-Cement ratio:
From the graph shown below, the water cement ratio
required for the target mean strength of 26.6Mpa is 0.50. This is lower than the maximum
value of 0.55 prescribed for Mild exposure adopt W/C ratio of 0.50.







5. Selection of Water and sand content:
From Appendix 3, for 20mm maximum size aggregate
,Sand conforming to grading zone II.

Water content per cubic meter of concrete = 186kg and
Sand content as percentage of total agg.
By absolute volume = 35%
25


From Appendix 5, for change in value in W/c ratio, compacting factor, for sand
belonging to Zone III, following adjustment is required:-


Therefore required sand content as percentage of total aggregate by absolute
volume
= 35 - 3.5 = 31.5%
Required Water content = 186 + 5.58 =191.6 l/m
3


6. Determination of cement content:-
Water-Cement ratio = 0.50
Water =191.6 liters

Cement =

= 383 kg/m
3

From Appendix 4, this cement content is adequate for MILD exposure conditions.

7. Determination of coarse and fine aggregate contents: From table 1, for the specified
maximum size of aggregate of 20mm, the amount of entrapped air in the wet concrete is 2 %.
Taking this in to account and applying the given equation:-

Change in condition % adjustment required
App Water content sand in total aggregate
For decrease in water cement
Ratio by(0.60-0.50) that is 0.1 0 -2.0

For increase in compacting factor
(0.90-0.80), that is 0.10 +3 0

For sand conforming to Zone III
Of table 4, IS: 383-1970 0 -1.5
Total +3 -3.5
26






Where
V = Absolute volume of concrete, which is equal to
Gross volume (m
3
) minus the volume of
Entrapped air,
W = mass of water (kg)/m
3
of concrete,
C = mass of cement (kg)/m
3
of concrete
S
c
= Specific gravity of cement
P = Ratio of FA to total aggregate by absolute volume
f
a
,C
a
= Total masses of FA and CA (kg)/m
3
of concrete
Respectively and
S
fa
, S
ca
= Specific gravities of saturated, surface dry FA & CA.
Table 1:- Approximate Entrapped air content

Maximum size of Entrapped air, as percentage of Aggregate(mm)
Volume of concrete
10 3.0
20 2.0
40 1.0

C
a
=

C
a =

f
a
= 546kg/m
3


C
a
= 1188kg/m
3

27

The mix proportion the becomes:-

Water Cement Fine aggregate Coarse aggregate
191.6 383 546 1188
0.50 1 1.425 3.10

8. Actual quantities required for the mix per bag of cement:

The mix is 0.50 : 1.0 :1.425 :3.10. For 50 kg of cement, the quantity of
materials is worked out as below;

1. Cement = 50 kg
2. Sand = 71.0kg
3. Coarse aggregate(CA) = 155 kg Fraction I =60% = 93 kg
i. Fraction II =40% = 62 kg
4. Water

For w/c ratio of 0.50, quantity=25 liters of water.

a) Extra quantity of water to be added for absorption in case of CA, at 0.5 percent mass =
0.77 liters.

b) Quantity of water to be deducted for moisture present in sand, at 2 per cent by mass =
1.42 liters.

c) Actual quantity of water required to be added

= 25.0 + 0.77 - 1.42 = 24.35 liters.

d) Actual quantity of sand required after = 71.0 + 1.42
Allowing for mass of free moisture = 72.42 kg.

e) Actual quantity of CA required

Fraction I = 93 - 0.46 = 92.54 kg.
Fraction II = 62 - 0.31 =61.69 kg.
28




Therefore the actual quantities of different constituents required for one bag mix are

Water : 24.35 kg
Cement : 50.00 kg
Sand : 72.72 kg
CA
1. Fraction I : 92.54 kg
2. Fraction II : 61.69 kg

















29





Trial mix
A typical trial mix test program is given in table below:



Quantity of materials per cubic meter of concrete Concrete characteristics
Mix
No.
Cement Water Sand C
Type
I
A
Type
II
Workab
-ility
(CF)
Visual
Observ-
ation
28 days
compre-
ssive
strengt-h
1 2 3 4 5 6 7 8 9
(Kg) (L) (kg) (kg) (Kg) N/mm2

1

383
191.6
w/c = 0.5
546
(31.5%)
712 475 0.80 Under
sanded

_

2

394.6
197.3
w/c=
0.5
564
(33%)
687 458 0.91 Cohesive 28.8

3


358.7
197.3
w/c=
0.55
591
(34%)
688 459 0.90 Cohesive 26.0

4

438.4
197.3
w/c=
0.45
535
(32%)
682 455 0.89 Cohesive 31.2
30






Chapter VI
Superplasticizer used for mix design

31

6.1 Sikament 170 (High Performance Plasticizer):-
6.1.1. Description:
Sikament 170 is a purpose designed material which is a chemical combination of
Modified Lignosulphonates.
Sikament 170 allows the manufacture of economic high quality concrete without
undesirable side effects.
Sikament 170 is a ready to use liquid for producing a more uniformly cohesive quality
concrete to meet the specifications and needs of Architects, Consulting Engineers and
Contractors.
Complies with EN 934 Part 2 Table 3.1/3.2 - High Range Water
Reducing/Superplasticising Admixtures.
6.1.2. Uses:
Readymix concrete

Precast concrete

Pumped concrete

Lightweight concrete

Wet shotcrete

Semi-dry concrete

6.1.3. Advantages:
Improved workability/reduces w/c ratio
Flexible high performance plasticizer
High resistance to segregation/reduces bleeding
Improved surface finish
Reduces shrinkage cracking potential
Higher initial and ultimate compressive strengths
Higher durability concrete

32

6.1.4. Method of use:
For maximum dispersion Sikament 170 should be added with the mixing water, on no account
should it be added to the dry cement. Where concrete is being mixed by ready mixed trucks,
Sikament 170 can be added at the batching plant but the trucks must rotate their drums until a
uniform mix is achieved. To produce flowing concrete a well proportioned pump mix should be
used.
6.1.5. Dosage:
The dosage rate of Sikament 170 is best found after initial site trials, which will take into
consideration the best performance/dosage rate. As a guide an addition rate of between 0.30.5%
by weight of cement is recommended (i.e. 0.150.25 liters per 50 Kg).
6.1.6. Compressive Strength Results (typical):

Admixture Dose
(ml/50 Kg
Cement)
w/c ratio Slump
(mm)
Air content
%
28 day
compressive
strength
(N/mm
2
)
Control None 0.65 75 0.8 42.5
Sikament 170 200 0.59 80 1.5 54

6.1.7. Effect on workability (typical):

Admixture Dose
(ml/50 Kg
Cement)
w/c ratio Slump
(mm)
Air content
%
28 day
compressive
strength
(N/mm
2
)
Control None 0.65 75 0.8 42.5
Sikament 170 200 0.65 Collapsed 1.5 43.0

33

6.2 Sikament NN(High range water-reducing concrete admixture):-

6.2.1 Description:

A highly effective dual action liquid super-plasticizer for the production of free flowing concrete
or as a substantial water-reducing agent for promoting high early and ultimate strengths.
Chloride free. Complies with IS 9103 99.

6.2.2. Uses:

Sikament NN is used as a superplasticizer in the production of free flowing concrete such as:

Slabs and foundation
Walls, columns and piers
Slender components with densely packed re-inforcements
Textured surface finishes

It is also used as a water-reducing agent leading to high early strength concrete such as:

Pre-cast concrete elements
Pre-stressed concrete
Bridges and cantilever structures
Areas of concrete where form work must be removed quickly or early loading applied

6.2.3. Advantages:

Workability is greatly improved
Increased place ability in slender components with packed reinforcement
Decrease the extent of vibration
Normal set without retardation
Significantly reduces the risk of segregation as a Water Reducer
Upto 20% water reduction
28 days strengths improved by around 40%

6.2.4 Technical data:

Chemical Base - Modified Melamine Formaldehyde
Relative Density - 1.20 kg/l at 30C
Appearance / Colour - Dark brown liquid
Packaging - 120 kg , 150 kg
34


6.2.5 Dosage:

0.5 - 2.0% depending on requirements, concerning workability and strength. Sikament NN is
compatible with all types of Portland Cement including SRC. Actual dosage to be finalized on
the basis of site trials.

6.2.6 Storage:

12 months from date of production if stored properly in undamaged unopened, original sealed
packaging, in dry conditions at temperatures between +5C and +30C. Protect from direct
sunlight and frost.





















35












Chapter VI I
Results

36

7. Results:-
7.1. Results of standard mix:


Cubes Dial gauge
reading(KN)
Surface area of cube Strength of cube in days
7 28
1. 350 15cm x 15cm 15.55 25.65
2. 360 15cm x 15cm 16.00 26.4
3. 390 15cm x 15cm 17.33 28.59


Average strength of concrete in 7 days is= 16.30 N/mm
2

Average strength of concrete in 28 days is= 26.88 N/mm
2



7.2.Results of mix after adding superplasticizer(Sikament 170):

Cubes Dial gauge
reading(KN)
Surface area of cube Strength of cube in days
7 28
1. 400 15cm x 15cm 17.77 29.32
2. 380 15cm x 15cm 16.90 27.88
3. 380 15cm x 15cm 16.90 27.88


Average strength of concrete in 7 days is = 17.20 N/mm
2

Average strength of concrete in 28 days is = 28.36 N/mm
2


37


7.3. Results of mix after adding superplasticizer(Sikament NN, water reducer):

Cubes Dial gauge
reading(KN)
Surface area of cube Strength of cube in days
7 28
1. 400 15cm x 15cm 18.66 30.78
2. 380 15cm x 15cm 19.20 31.68
3. 380 15cm x 15cm 20.79 34.31

Average strength of concrete in 7 days is = 19.55 N/mm
2

Average strength of concrete in 28 days is = 32.25 N/mm
2


38









Chapter VI I I
Conclusion

39

8. Based on the analysis of the above results of mix design, following conclusions can be
drawn:


We are carrying out the concrete mix design by is code method using super plasticizer
with locally available materials , the project has provided the excellent opportunity to
gain the knowledge about the various aspects of mix design of concrete while working on
this project many new concepts and technical details have been encountered.

The mix using superplasticizer results a better concrete because it is not only increasing
the workability but also helps in getting better strength.

In our project we found that Sikament NN is better than Sikament 170 because it reduces
the water content in concrete by 20% and helps in increasing the strength of concrete
upto 40%.

We also found that Sikament NN improves the workability of concrete better than
Sikament 170.




40












Appendix
41

Appendix 1:- Values of Tolerance Factor (t) (Risk Factor)

Tolerance Level
No of samples

1 in 10

1 in 15

1 in 20

1 in 40

1 in 100
10
20
30
Infinite
1.37
1.32
1.31
1.28
1.65
1.58
1.54
1.50
1.81
1.72
1.70
1.64
2.23
2.09
2.04
1.96
2.76
2.53
2.46
2.33


Appendix 2:- Assumed Standard Deviation as per IS 456-2000




Grade of concrete

Assumed Standard
Deviation N/mm
2


M 10
M 15
M 20
M 25
M 30
M 35
M 40
M 45
M 50

3.5

4.00


5.00
42


Appendix 3:- Relation between free water cement ratio and concrete compressive strength
W/C =0.60, Workability =0.80 C.F.
(Slump 30mm approximately)
(Application for concrete upto grade M35)


Maximum Size Water content including Sand as percent of
Of aggregate surface water per cubic Total aggregate
(mm) Metre of concrete (kg) by absolute volume
10 200 40
20 186 35
40 165 30


Appendix 4:- Minimum cement content, Maximum W/C ratio and Minimum grade of
concrete for different exposures with normal Weight Aggregate of 20mm Nominal
maximum size . IS:456-2000
Sl. Exposure Plain concrete Reinforced concrete
No.
Minimum
cement
contents
kg/m
3

Maximum
free W/C
ratio
Minimum
grade of
concrete
Minimum
cement
contents
kg/m
3

Maximum
free W/C
ratio

1. Mild 220 0.60 - 300 0.55 M 20
2. Moderate 240 0.60 M 15 300 0.50 M 25
3. Severe 250 0.50 M 20 320 0.45 M 30
4. Very
severe
260 0.45 M 20 340 0.45 M 35
5. Extreme 280 0.40 M 25 360 0.40 M 20
43


Appendix 5:- Adjustment of value of Water content and sand percentage for other
conditions
Change in conditions Adjustment required in
Stipulated for tables Water content % sand in total

Aggregate
For sand conforming to grading Zone I +1.5 for
Zone I
Zone III or Zone IV of Table 4,IS: 0 -1.5% for
Zone III
383-1979 -3% for
Zone IV
Increase or Decrease in the value of
Compacting factor by 0.10 +3% 0
Each 0.05 increase or decrease in Water
-cement ratio 0 +1%
For Rounded aggregate -15 -7%


Appendix 6:- Fineness modulus of coarse and fine aggregate
Coarse Aggregate-
IS Sieve size Percent retained Cumulative percent
retained
Percentage passing
40mm 0.00 0.00 100.00
20mm 0.60 0.60 99.40
10mm 73.50 74.10 25.90
4.75mm 22.90 97.00 3.00

Fine Aggregate-
IS sieve size Percent retained Cumulative percent
retained
Percentage passing
10mm 0.00 0.00 100.00
4.75mm 5.20 5.20 94.80
2.36mm 3.00 8.20 91.80
1.18mm 8.60 16.80 83.20
600micron 25.80 42.60 57.40
300micron 32.80 75.40 24.60
150micron 20.70 96.10 3.90

44







Bibliography
45

B I B L I O G R A P H Y
Books :
(1) Prof. M.S. Shetty, Concrete Technology, S. Chand publications New Delhi,
Multicolour illustrative revised edition 2012

(2) A.M. Neville and J.J. Brook, Concrete Technology, Pitman Publishing Limited
London, revised edition 2009.

(3) S.K. Duggal, Building materials, New age publications, New Delhi, Third revised
edition 2008

Codes :
(1) IS 10262 Concrete Mix Design
Websites :
(1) www.engineeringcivil.com