10/21/2015

MixDesignForConcreteRoadsAsPerIRC:152011

MixDesignForConcreteRoadsAsPerIRC:152011
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By
KaushalKishore,MaterialsEngineer,Roorkee
ABSTRACT:
Thestressesinducedinconcretepavementsaremainlyflexural.Thereforeflexuralstrengthismoreoftenspecifiedthancompressivestrengthinthe
designofconcretemixesforpavementconstruction.Asimplemethodofconcretemixdesignbasedonflexuralstrengthfornormalweightconcrete
mixesisdescribedinthepaper.
INTRODUCTION:
Usualcriterionforthestrengthofconcreteinthebuildingindustryisthecompressivestrength,whichisconsideredasameasureofqualityconcrete.
However,inpavementconstructions,suchashighwayandairportrunway,theflexuralstrengthofconcreteisconsideredmoreimportant,asthestresses
inducedinconcretepavementsaremainlyflexural.Therefore,flexuralstrengthismoreoftenspecifiedthancompressivestrengthinthedesignof
concretemixesforpavementconstruction.Itisnotperfectlyreliabletopredictflexuralstrengthfromcompressivestrength.Further,variouscodesofthe
worldspecifiedthatthepavingconcretemixesshouldpreferablybedesignedinthelaboratoryandcontrolledinthefieldonthebasisofitsflexural
strength.Therefore,thereisaneedtodesignconcretemixesbasedonflexuralstrength.
Thetypeofaggregatecanhaveapredominanteffect,crushedrockaggregateresultinginconcretewithhigherflexuralstrengththanuncrushed(gravel)
aggregatesforcomparablemixes,assumingthatsoundmaterialsareused.Thestrengthofcementinfluencesthecompressiveandflexuralstrengthof
concretei.e.withthesamewatercementratio,higherstrengthcementwillproduceconcreteofhighercompressiveandflexuralstrength.
MIXDESIGNDETAILS
IRC:152011specifiedthatforconcreteroadsOPCshouldbeused.ThiscodealsoallowedPPCasperIS:1489(Part1)withflyashcontentnotmore
than20percentbyweightofPPC.AccordinglyOPC+flyashmaybeusedinconcreteroads.Flyashshallbenotmorethan20percentbyweightof
cementitiousmaterial.However,IS:4562000specifiedthatflyashconformingtograde1ofIS3812maybeusedaspartreplacementofOPC
provideduniformblendedwithcementisessential.Theconstructionsiteswherebatchingplantsareusedthismaybepracticable.Inordinarysiteswhere
mixerorhandmixingaredoneuniformblendingofflyashwithcementisnotpracticable.Atsuchconstructionsites,PPCmaybeused.PPCshouldbe
usedwithcautionwhererapidconstructionmethodslikeslipformisbeingused.Jointscuttingalsoneedearlystrength.
1
2

CharacteristicFlexuralStrength :
at28days
Cement
:

4.5N/mm2
Threemixesaretobedesigned
MIXA
WithPPC(Flyash18percentbased)
conformingtoIS:1489partI1991.7days
strength37.5N/mm2.SpecificGravity:
3.00
MIXB
WithOPC43GradeconformingtoIS:
81121989.7daysstrength40.5n/mm2.
SpecificGravity:3.15
MIXC
WithOPCofMixBandFlyash
conformingtoIS:3812(PartI)2003
SpecificGravity:2.20

Flyashreplacement

Maximumnominalsizeof
:
aggregates
Fineaggregateandcoarse
:
aggregategrading
Minimumcementcontentfor4.5 :
N/mm2characteristicflexural
strength:

5
6

Note:Requirementsofallthethreemixes
arethesame.FineAggregate,Coarse
AggregateandRetarderSuperplasticizer
arethesameforallthethreemixes.
20%Flyashisrequiredtobereplacedwith
thetotalcementitiousmaterials.
31.5mmCrushedaggregate
GiveninTable1
(a)OPCshallnotbelessthan360kg/m3.
(b)PPCshallnotbelessthan425kg/m3.

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Flyashinit20%maximumbyweightof
totalcementitiousmaterials
(c)OPC+FlyashmixOPCshallnotbe
lessthan340kg/m3.Flyash20%maximum
byweightofcementationsmaterial
7

MaximumfreeW/CRatio

(a)ForOPC0.45
(b)ForPPC0.50

Workability

9
10
11
12

Exposurecondition
Methodofplacing
Degreeofsupervision
Maximumofcementcontent

:
:
:
:

40mmslumpatpourtheconcretewillbe
transportedfromcentralbatchingplant
throughtransitmixer,atadistanceof15
KmduringJune,Julymonths.Theaverage
temperaturelastyearduringthesemonths
was300C.
Moderate
Fullymechanisedconstruction
Good
(a)OPC425kg/m3
(b)PPC425kg/m3

13

Chemicaladmixture

14

ValuesofZx(forNational
Highway)

RetarderSuperplasticizerconformingto
IS:91031999.Withthegivenrequirements
andmaterials,themanufacturerofRetarder
Superplasticizerrecommendsdosagesof
1%bwofOPC,whichwillreduce15%of
waterwithoutlossofworkability.Forfly
ashincludedcementdosageswillbe
requiredtobeadjustedbyexperience/
trials.2%maximumbyweightof
cementitiousmaterial
1.96x0.40

TESTDATAFORMATERIALSANDOTHERDETAILS
1.Thegradingoffineaggregate,1&2aggregatesareasgiveninTable.1.
2.Propertiesofaggregates
Tests
SpecificGravity
WaterAbsorption%

Fineaggregate

Aggregate1

Aggregate2

2.65

2.65

2.65

0.8

0.5

0.5

3.TargetaverageflexuralstrengthforallA,BandCmixes
S=S+Zq
=4.5+1.96x0.40
=5.3N/mm2at28daysage
4.ForMixA,BandCfreeW/Cratiowithcrushedaggregateandrequiredaverageflexuraltargetstrengthof5.3N/mm2at28daysfromFig.1CurveD
foundtobe0.42.ThisislowerthanspecifiedmaximumW/Cratiovalueof0.45forOPCand0.50forPPC.
Note:
Inabsenceofcementstrength,butcementconformingtoISCodes,assumefromFig.1
CurveCandDforOPC43Grade
TakecurvesCandDforPPC,asPPCisbeingmanufacturedinminimumof43Gradeofstrength.
5.Otherdatas:TheMixesaretobedesignedonthebasisofsaturatedandsurfacedryaggregates.Atthetimeofconcreting,moisturecontentofsite
aggregatesaretobedetermine.Ifitcarriessurfacemoisturethisistobedeductedfromthemixingwaterandifitisdryaddinmixingwaterthequantity
ofwaterrequiredforabsorption.Theweightofaggregatesarealsoadjustedaccordingly.
DESIGNOFMIXAWITHPPC
a)FreeW/Cratioforthetargetflexuralstrengthof5.3N/mm2asworkedoutis0.42forfirsttrial.
b)Freewaterfor40mmslumpfromTable2for31.5mmmaximumsizeofaggregate.
2/3170+1/3200=180kg/m3
FromtrialsitisfoundthatRetarderSuperplasticizeratadosagesof1.3%bwofPPCmayreduce15%waterwithoutlossofworkability
Thenwater=180(180x0.15)=153kg/m3
c)PPC=153/0.42=364kg/m3(RequiredminimumPPCis425kg/m3)
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d)Formulaforcalculationoffreshconcreteweightinkg/m3
Um=10xGa(100A)+Cm(1Ga/Gc)Wm(Ga1)
Where,
Um=Weightoffreshconcretekg/m3
Ga=Weightedaveragespecificgravityofcombinedfineandcoarseaggregatebulk,SSD
Gc=Specificgravityofcement.Determineactualvalue,inabsenceassume3.15forOPCand3.00forPPC(Flyashbased)
A=Aircontent,percent.Assumefortrialentrappedair1.5%
For31.5mmmaximumsizeofaggregate
Thereisalwaysentrappedairinconcrete.ThereforeignoringentrappedairvalueasNILwillleadthecalculationofhighervalueofdensity.Takeexact
valueofairasobtainedinthetest
Wm=Mixingwaterrequiredinkg/m3
Cm=Cementrequired,kg/m3
Note:Theexactdensitymaybeobtainedbyfillingandfullycompactingconstantvolumesuitablemetalcontainerfromthetrialbatchesofcalculated
designmixes.Themixbealteredwiththeactualobtaineddensityofthemix.
Um=10xGa(100A)+Cm(1Ga/Gc)Wm(Ga1)
=10x2.65(1001.5)+425(12.65/3.00)153(2.651)
=2409kg/m3
e)Aggregates=2409425153=1831kg/m3
f)Fineaggregate=1831x0.45=824kg/m3
Aggregate1=1831x0.29=531kg/m3
Aggregate2=1831x0.26=476kg/m3
g)Thusfor4.5N/mm2flexuralstrengthquantityofmaterialspercu.m.ofconcreteonthebasisofsaturatedandsurfacedryaggregates:
Water=153kg/m3
PPC=425kg/m3
FineAggregate(sand)=824kg/m3
Aggregate(1)=531kg/m3
Aggregate(2)=476kg/m3
RetarderSuperPlasticizer1.3%bwofPPC=5.525kg/m3
MIXBWITHOPC
a)Water=180(180x0.15)=153kg/m3
b)OPC=153/0.42=364kg/m3
c)Density:10x2.65(1001.5)+364(12.65/3.15)153(2.651)=2416kg/m3
d)TotalAggregates=2416364153=1899kg/m3
Aggregate1=1899x0.29=551kg/m3
Aggregate2=1899x0.26=494kg/m3
FineAggregate=1899x0.45=854kg/m3
e)Thusfor4.5N/mm2flexuralstrengthquantityofmaterialspercu.mofconcreteonthebasisofSSDaggregatesaregivenbelow:
Water=153kg/m3
OPC=364kg/m3
FineAggregate(sand)=854kg/m3
Aggregate(1)=551kg/m3
Aggregate(2)=494kg/m3
RetarderSuperPlasticizer1%bwOPC=3.640kg/m3
MIXCWITHOPC+FLYASH
Withatotalcementitiousmaterialof430kg/m3,
OPC=430x0.80=344kg/m3
Flyash=430x0.20=86kg/m3
MixonthebasisofSSDAggregates,
(1)Waterasworkedoutearlier=153kg/m3
(2)OPC=344kg/m3
(3)Flyash=86kg/m3
Density=10x2.65(1001.5)+430(12.65/3.00)153(2.651)=2410kg/m3
TotalAggregates=241015334486=1827kg/m3
(4)Fineaggregate0.45x1827=822kg/m3
(5)Aggregate(1)0.29x1827=530kg/m3
(6)Aggregate(2)0.26x1827=475kg/m3
(7)Retardersuperplasticizer1.5%bwofcementitiousmaterial=6.450kg/m3
Note:
(1)CementitiousmaterialworkedoutasperIRC:152011,whichspecified:Incaseflyash(asperIS:3912Part1)isblendedatsite,thequantityoffly
ashshallberestrictedto20percentbyweightofcementitiousmaterialandthequantityofOPCinsuchablendshallnotbelessthan340kg/m3.
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(2)Afterthefirsttrialmix,itsactualdensityistobedetermined,asspecifiedelasewhereinthispaper.Themixproportionsshallthenbeworkedout
accordinglyincludingthewatercontent,thedosagesofRetarderSPforrequiredworkabilitykeepingthefreew/cratiowithinthepermissiblelimitsand
adjustingitaccordingtotherequiredflexuralstrength.
(3)Themixproportionsgiveninthispaperareforfirsttrialandtobeadjustedasperactualsitematerials,conditionsandrequirements.
For4.5N/mm2flexuralstrengthquantityofmaterialpercu.mofconcreteonthebasisofsaturatedandsurfacedryaggregatesofMixA,B
andcaregivenbelow:

Materials
Waterkg/m3
PPCkg/m3
OPCkg/m3
Flyashkg/m3
FineAgg.kg/m3
Agg.(1)kg/m3
Agg.(2)kg/m3
RetarderSuperplasticizer
kg/m3
W/Cementitiousratio

MIX.AwithPPC Mix.BwithOPC

Mix.Cwith
OPC+Flyash

153

153

153

425

364

344

86

824

854

822

531

551

530

476

494

475

5.525

3.640

6.450

0.36

0.42

0.356

Note:
1.ForexactW/Cratiothewaterinadmixtureshouldalsobetakenintoaccount.
2.PPCreduces5%waterdemand.Ifthisisfoundbytrialthentakereducewaterforcalculation.
3.Ifthetrialmixesdoesnotgivestherequiredpropertiesofthemix,itisthenrequiredtobealteredaccordingly.However,whentheexperiencesgrows
withtheparticularsetofmaterialsandsiteconditionsveryfewtrialswillberequired,andaexpertofsuchsiteveryrarelywillberequireda2ndtrial.
CONCLUSION
1.For4.5N/mm2flexuralstrengthconcretehavingsamematerialandrequirement,butwithoutwaterreducer,theOPCrequiredwillbe180/0.42=429
kg/m3
2.WiththeuseofsuperplasticizerthesavinginOPCis65kg/m3andwater27lit/m3.
3.Inthefinancialyear20092010Indiahasproduces200milliontonnesofcement.InIndiaonekgofcementproduceemitted0.93kgofCO2.Thusthe
productionof200milliontonnesofcementhademitted200x0.93=186milliontonnesofCO2totheatmosphere.
4.If50milliontonnescementinmakingconcreteusesWaterReducers7500000tonnesofcementcanbesaved.3750000KLofpotablewaterwillbe
savedandthesavingofRs.3300croresperyeartotheconstructionIndustry.6975000tonnesofCO2willbepreventedtobeemittedtotheatmosphere.
Thebenefitsintheusesofwaterreducersnotlimitedtothis.Whenwaterreducesshrinkageandporosityofconcretearereduceswhichprovidesthe
durabilitytoconcretestructures.
5.Indiaisfacingseriousair,water,soil,foodandnoisepollutionproblems.Everyeffortsthereforearenecessarytopreventpollutionontoppriority
basis.
6.Asthestressinducedinconcretepavementsaremainlyflexural,itisdesirablethattheirdesignisbasedontheflexuralstrengthofconcrete.The
qualityofconcreteisnormallyassessedbymeasuringitscompressivestrength.Forpavings,however,itistheflexuralstrengthratherthanthe
compressionstrengthofconcretewhichdeterminethedegreeofcrackingandthustheperformanceofroad,anditisimperativetocontrolthequalityon
thebasisofflexuralstrength.
7.AsperIRC:152011,incaseofsmallsizeprojects,wherefacilitiesfortestingbeamswiththreeprintloadingarenotavailable,insuchcases,themix
designmaybecarriedoutbyusingcompressivestrengthvaluesandthereafterflexuralstrengthwillbedeterminedaspercorrelationbetweenflexural
strengthwithcompressivestrengthgiventhefollowingequation.
WherefcristheflexuralstrengthinMPaorN/mm2andfckisthecharacteristiccompressivestrengthinMPaorN/mm2asperIS:4562000.
REFERENCES:
1

IS:3831970

IS:4562000

Specificationsforcoarseandfineaggregates
fromnaturalsourcesforconcrete(second
revision)BIS,NewDelhi
Codeofpracticeforplainandreinforced

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3
4
5
6
7
8
9

10
11
12
13
14
15
16
17
18
19

MixDesignForConcreteRoadsAsPerIRC:152011

concrete(fourthrevision),BIS,NewDelhi
Specificationforadmixturesforconcrete(first
revision)BIS,NewDelhi
IS:81121989
Specificationsfor43Gradeordinaryportland
cement(firstrevision)BIS,NewDelhi
IS:2386(PartIII)1963
methodoftestforaggregateforconcrete.
Specificgravity,density,voids,absorptionand
bulking,BIS,NewDelhi
IS:3812(PartI)2003
Specificationforpulverizedfuelash:PartIfor
useaspozzolanaincement,cementmortarand
concrete(secondrevision)BIS,NewDelhi
IS:1489PartI1991
Specificationsforportlandpozzolanacement
(PartI)Flyashbased.(Thirdrevision),BIS,
NewDelhi
IRC:152011Standardspecificationsandcodeofpracticeforconstructionof
concreteroad(Fourthrevision)
KishoreKaushal,ConcreteMixDesignBasedonFlexuralstrengthforAir
EntrainedConcrete,Proceedingof13thConferenceonourWorldinConcrete
andStructures,2526,August,1988,Singapore.
KishoreKaushal,MethodofConcreteMixDesignBasedonFlexural
Strength,ProceedingoftheInternationalConferenceonRoadandRoad
TransportProblemsICORT,1215December,1988,NewDelhi,pp.296305.
KishoreKaushal,MixDesignBasedonFlexuralStrengthofAirEntrained
Concrete.TheIndianConcreteJournal,February,1989,pp.9397.
KishoreKaushal,ConcreteMixDesignContainingChemicalAdmixtures,
JournaloftheNationalBuildingOrganization,April,1990,pp.112.
KishoreKaushal,ConcreteMixDesignforRoadBridges,INDIAN
HIGHWAYS,Vol.19,No.11,November,1991,pp.3137
KishoreKaushal,MixDesignforPumpedConcrete,JournalofCentralBoard
ofIrrigationandPower,Vol.49,No.2,April,1992,pp.8192
KishoreKaushal,ConcreteMixDesignwithFlyAsh,IndianConstruction,
January,1995,pp.1617
KishoreKaushal,HighStrengthConcrete,BulletinofIndianConcrete
InstituteNo.51,AprilJune,1995,pp.2931
KishoreKaushal,ConcreteMixDesignSimplified,IndianConcreteInstitute
BulletinNo.56,JulySeptember,1996,pp.2530.
KishoreKaushal,ConcreteMixDesignwithFlyAsh&Superplasticizer,ICI
BulletinNo.59,AprilJune1997,pp.2930
KishoreKaushal.MixDesignforPumpedConcrete,CE&CROctober,2006,
pp.4450.
IS:91031999

Table.1:GradingofAggregates
ISSieve
Designation

Percentageofpassingbymass
Fine
aggregate
fromriver

29%

45%
31.50mm
26.50mm
19.0mm
9.50mm
4.75mm
600micron
150micron
75micron

Crushedaggregate
(1)
(2)

Combined
gradingof
mix

26%

IRC:152011
recommendedgrading
ofcombinedaggregates
forpavementquality
concrete(PQC)

100

100

100

100

100

100

100

98

99

8595

100

100

25

81

6888

100

46

58

4565

94

44

3055

42

19

830

10

515

05

Table.2:Approximatefreewatercontent(kg/m3)requiredtogivevariouslevelsofworkabilityfornonairentrained(withnormalentrapped
air)concrete.
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Maximumsizeof
aggregate(mm)

MixDesignForConcreteRoadsAsPerIRC:152011

Typeof
aggregate
Uncrushed

Slump(mm)

40+1031.5
25+10

Crushed

160

170

190

200

Note:Whencoarseandfineaggregateofdifferenttypesareused,thefreewatercontentisestimatedbytheexpression.
2/3Wf+1/3Wc
Where,
Wfsub>=FreewatercontentappropriatetotypeoffineAggregate
AndW c=Freewatercontentappropriatetotypeofcoarseaggregate.

Weatengineeringcivil.comarethankfultoEr.KaushalKishoreforsubmittingtherevisedmixdesignasperIRC:152011.Thiswillbeofgreathelpto
allcivilengineeringstudentsandfacultywhoareseekinginformationonmixdesignbasedonrevisedIRC.
MoreEntries:
MixDesignForM35GradeOfConcrete
UnderstandingNominalandDesignMixes
MixDesignM50Grade
MixDesignForConcreteRoadsAsPerIRC152002
MixDesignWithSuperplasticizers
MixDesignM40Grade
ListOfResearchPublicationsOfKaushalKishore
ConcreteMixDesignM60
Comments
FarhanJuly20,2013at1:35pm
Thankyousirforyourvaluableinformation
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ReplyLinkQuote
OmonaRichardNovember4,2013at12:33pm
Whatisvolumeofmaterialstobeusedin1cubicmeterofconcrete
One(1cubicmeter)ofconcreteishowmanykilogrameofmaterialsinside
ReplyLinkQuote
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