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  1. Home/
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  3. Project on Concrete Mix Design for various grades of Concrete

Project on Concrete Mix Design for various grades of Concrete

  AIM: To Calculate the Concrete Mix Design for M35 grade concrete with fly ash & M50 grade concrete without Fly ash INTRODUCTION:Concrete mix design is the method of finding the precise proportion of cement, sand and aggregates for concrete to achieve the target strength in structures, therefore concrete…

    • Md Sameer

      updated on 30 Aug 2022

     
    • AIM: To Calculate the Concrete Mix Design for M35 grade concrete with fly ash & M50 grade concrete without Fly ash

       

      INTRODUCTION:

      Concrete mix design is the method of finding the precise proportion of cement, sand and aggregates for concrete to achieve the target strength in structures, therefore concrete mix design can be stated as concrete mix in terms of cement: sand: aggregates. The design is done according to the requirements of concrete strength. So, we can achieve the desirable properties of concrete either it is in fresh stage or in hardened stage. The fresh concrete properties like workability, setting time and hardened concrete properties like compressive strength, durability etc. are attained surely by this method. Use of additives like admixtures, retarders etc. other than basic ingredients are used to improve the properties of mix. This project consist of two parts, the first part deals with the design of M35 grade cement with fly ash as a part of it and second part is the design of M50 grade concrete without fly ash.

      OBJECTIVE:

      The objective of this project is to produce a mix design for M35 grade concrete containing fly ash and M50 grade concrete. The mix will be prepared as per IS METHOD: Concrete mix proportioning guidelines from IS 10262:2009 and recommented guide lines from IS 10262:1982.

      EQUATIONS USED:

      1)Target mean strength

      f’ck =fck + 1.65s

      Where

      f’ck = target average compressive strength at 28 days
      fck = characteristics compressive strength at 28 days, and
      s = standard deviation
      2)Cement content

      Cement content = water content / water-cement ratio

      3) Volume Calculations

      (a) Volume of concrete
      (b) Volume of cement = [Mass of cement] / [Specific Gravity of Cement] x 1/1000
      (c) Volume of water = [Mass of water] / [Specific Gravity of water] x 1/1000
      (d)Volume of chemical admixture = [Mass of admixture] / [Specific Gravity of admixture] x 1/1000
      (e) Volume of all in aggregate =[a-(b+c+d)]
      (f) Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of Fine Aggregate x 1000
      (g) Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000
     
     
    PART 1:To Calculate the Concrete Mix Design for M35 grade concrete with fly ash:

    M35 grade concrete with Fly ash

    STEP 1: Stipulations for Concrete design mix

    Grade designation

    M35

    Type of cement

    OPC 43 Grade confirming to IS 8112

    Type of mineral admixture

    Fly ash confirming to IS 3812 (Part 1)

    Maximum nominal size of aggregate

    20 mm

    Minimum cement content

    320 kg/m3 (Table 5 of  IS 456:2000- Exposure condition)

    Maximum water-cement ratio

    0.45 (Table 5 of IS 456:2000 Exposure   condition)

    Workability

    100 mm (slump value for pumpable concrete)

    Exposure condition

    Severe (For Reinforced Concrete)

    Method of concrete placing

    Pumping

    Degree of supervision

    Good

    Type of aggregate

    Crushed Angular Aggregates

    Maximum cement content

    450 kg/m3

    Chemical admixture type

    Super Plasticizer

     

    STEP 2: TEST DATA FOR MATERIALS

    Cement used

    OPC 43 Grade conforming IS 8112

    Specific gravity of cement

    3.15

    Fly ash

    confirming to IS 3812 (Part 1)

    Specific gravity of fly ash

    2.2

    Chemical admixture

    Super Plasticizer conforming to IS 9103

    Specific gravity of coarse aggregate

    2.74

    Specific gravity of fine aggregate

    2.74

    Water absorption of coarse aggregate

    0.5%

    Water absorption of fine aggregate

    1.0%

    Free surface moisture of Coarse aggregate

    Nil

    Free surface moisture of  Coarse aggregate

    Nil

    Sieve analysis: Coarse aggregate

    Conforming to Table 2 of IS 383

    Sieve analysis: Fine aggregate

    Conforming to Grading Zone II of Table 4 of IS 383

     

    STEP 3: TARGET STRENGTH FOR MIX PROPORTIONING

    f’ck =fck + 1.65s

    Where

    f’ck = target average compressive strength at 28 days
    fck = characteristics compressive strength at 28 days, and
    s = standard deviation
    From Table I of IS 10262:2009, Standard Deviation, s = 5 N/mm2.

    35 + 1.65 x 5 = 43.25 N/mm2

     

    Target mean strength = 43.25 N/mm2

     

    STEP 4: SELECTION OF WATER-CEMENT RATIO

    The maximum water-cement ratio to design M50 grade concrete can be found from Table 5 of IS 456-2000.

    Maximum W/C ratio =0.45

    Based on experience adopted water cement ratio is .44

    0.44<0.45, hence ok

    Adopted W/C ratio=0.44

     

    STEP 5: SELECTION OF WATER CONTENT

    From Table 2 of IS 10262:2009, maximum water content for 20 mm aggregate

    186 litre (for 25 to 50 mm slump range)

    Clause 4.2 suggests increasing of 3% of water content for every extra 25mm slump from 50mm slump. So a 6% is to be added to it

    Estimated water content for 100 mm slump

    186+ (6/100)*186 = 197 litre.

    (Note: If Super plasticizer is used, the water content can be reduced up to 20% and above.)

    Based on trials with Super plasticizer water content reduction of 20% has been achieved, Hence the arrived water content

    197*0.8 = 158 litre

    Water required 158 litres

     

    EP 6: CALCULATION OF CEMENT AND FLY ASH REQUIRED

    Adopted w/c Ratio

    0.44

    Total cementitious (Cement + fly ash)requirement =

    Water content/ Water Cement ratio

    158/0.44 = 359 kg/m3

    The cementitious content has to be increased in order to attain good workability and strength. The increment required is determined on the basis of experience and research. Here we are increasing cementitious content by 10%

    Final cementitious content

    359 X 1.10 = 395 kg

    From Table 5 of IS 456, Minimum cement content for ‘Severe’ exposure conditions

    320 kg

    395 kg/m3 > 320 kg/m3 hence ok.

    Cementitious material content

    395

    New water cement ratio

    158/395 =0.4

    Fly ash content is taken as 30% of the total cementitious content

    395 X .3 = 118.5 kg/m3

    Cement required

    395 – 118 = 277 kg/m3

    Cement quantity saved due to fly ash addition

    350-277 = 73 kg/m3

    Cementitious material, cement  and fly ash required is 395 kg/m3 , 277 kg/m3and 118 kg/m3 and the new water-cement ratio is 0.4 respectively

     

     

    STEP 7: VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

    From Table 3 of (IS 10262:2009) Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II) for water-cement ratio of 0.50 is

    0.62.

    In the present case water-cement ratio is 0.44. Therefore, volume of coarse aggregate is required to be increased to decrease the fine aggregate content. As the water-cement ratio is lower by 0.06. The proportion of volume of coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio).

    Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.44

    0.632

    For pumpable concrete these values should be reduced up to 10%. Therefore, volume of coarse aggregate

    0.632 x 0.9 =0.568.

     

    Volume of fine aggregate content

    1 – 0.568 =0.431

    Volume of fine aggregate and coarse aggregate is  0.431 and .568

     

     STEP 8: MIX CALCULATIONS

    The mix calculations as per unit volume of concrete shall be as follows:

    a) Volume of concrete

    1 m3

    b) Volume of cement = [Mass of cement] / [Specific Gravity of Cement] x 1/1000

    (277/3.15) X (1/1000) =0.087m3

    c) Volume of fly ash = [Mass of  fly ash] / [Specific Gravity of fly ash] x 1/1000

    (118/2.2) X (1/1000) =0.053

    d) Volume of water = [Mass of water] / [Specific Gravity of water] x 1/1000

    (158/1) X (1/1000) = 0.158m3

    e) Volume of chemical admixture = [Mass of admixture] / [Specific Gravity of admixture] x 1/1000

    (7.6/1.145) X (1/1000) =0.006 m3

     

    f) Volume of all in aggregate = 

    [a-(b+c+d+e)]

    [1-(0.087+0.053+0.158+0.006)] = 0.696m3

    g) Mass of coarse aggregate= f x Volume of Coarse Aggregate x Specific Gravity of Fine Aggregate x 1000

    0.696x 0.568 x 2.74 x 1000 = 1077 kg/m3

    h) Mass of fine aggregate= f x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000

    0.696x 0.431x 2.74 x 1000 = 822 kg/m3

    STEP 9: MIX PROPORTIONS

    Cement

    277 kg/m3

    Fly ash

    118 kg/m3

    Water

    158 l/m3

    Fine aggregate

    822 kg/m3

    Coarse aggregate 20mm

    1077 kg/m3

    Chemical admixture

    7.18 kg/m3

    Water-cement ratio (lowest W/C ratio is selected)

    0.4 
     
    Mix Proportion By weight

    1:2.08:2.72

    STEP 10: The slump shall be measured, the water content and dosage of admixture shall be adjusted for achieving the required slump on trial. The mix proportion shall be reworked for the actual water content and checked for durability requirements

    STEP 11: Two more trials having variation of 10% of water-cement ratio shall be carried out and a graph between three water- cement ratios and corresponding strengths shall be plotted to work out the mix proportions for the given target for field trials.

     

    PART 2:To Calculate the Concrete Mix Design for M50 grade concrete without fly ash:

     

    M50 grade concrete without Fly ash

    STEP 1: Stipulations for Concrete design mix

    Grade designation

    M50

    Type of cement

    OPC 53 Grade confirming to IS BIS 12269 - 1987

    Maximum nominal size of aggregate

    20 mm

    Minimum cement content

    320 kg/m3 (Table 5 of  IS 456:2000- Exposure condition)

    Maximum water-cement ratio

    0.45 (Table 5 of IS 456:2000 Exposure   condition)

    Workability

    100 mm (slump value for pumpable concrete)

    Exposure condition

    Severe (For Reinforced Concrete)

    Method of concrete placing

    Pumping

    Degree of supervision

    Good

    Type of aggregate

    Crushed Angular Aggregates

    Maximum cement content

    450 kg/m3

    Chemical admixture type

    Super Plasticizer

     

    STEP 2: TEST DATA FOR MATERIALS

    Cement used

    OPC 53 Grade conforming IS 12269-1987

    Specific gravity of cement

    3.15

    Chemical admixture

    Super Plasticizer conforming to IS 9103

    Specific gravity of coarse aggregate

    2.74

    Specific gravity of fine aggregate

    2.64

    Water absorption of coarse aggregate

    0.5%

    Water absorption of fine aggregate

    1.0%

    Free surface moisture of Coarse aggregate

    Nil

    Free surface moisture of  Coarse aggregate

    Nil

    Sieve analysis: Coarse aggregate

    Conforming to Table 2 of IS 383

    Sieve analysis: Fine aggregate

    Conforming to Grading Zone II of Table 4 of IS 383

    STEP 3: TARGET STRENGTH FOR MIX PROPORTIONING

    f’ck =fck + 1.65s

    Where

    ·        f’ck = target average compressive strength at 28 days

    ·        fck = characteristics compressive strength at 28 days, and

    ·        s = standard deviation

    From Table I of IS 10262:2009, Standard Deviation, s = 5 N/mm2.

    50 + 1.65 x 5 = 58.25 N/mm2

    Target mean strength = 58.25 N/mm2

    STEP 4: SELECTION OF WATER-CEMENT RATIO

    The maximum water-cement ratio to design M50 grade concrete can be found from Table 5 of IS 456-2000 for severe exposure.

    Maximum W/C ratio =0.45

    Based on experience adopted water cement ratio is .44

    0.44<0.45, hence ok

    Adopted W/C ratio=0.44

    STEP 5: SELECTION OF WATER CONTENT

    From Table 2 of IS 10262:2009, maximum water content for 20 mm aggregate

    186 litre (for 25 to 50 mm slump range)

    Clause 4.2 suggests increasing of 3% of water content for every extra 25mm slump from 50mm slump. So a 6% is to be added to it

    Estimated water content for 100 mm slump

    186+ (6/100)*186 = 197 litre.

    (Note: If Super plasticizer is used, the water content can be reduced up to 20% and above.)

    Based on trials with Super plasticizer water content reduction of 20% has been achieved, Hence the arrived water content

    197 X 0.8 = 158 litre

    Water required 158 litres

    EP 6: CALCULATION OF CEMENT REQUIRED

    Adopted w/c Ratio

    0.44

    Cement Content

    158/0.44 = 359 kg/m3

    From Table 5 of IS 456, Minimum cement content for ‘Severe’ exposure conditions

    320kg/m3

    359 kg/m3 > 320 kg/m3 hence ok.

    Cement required is  359 kg/m3 

     

    STEP 7: VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

    From Table 3 of (IS 10262:2009) Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II) for water-cement ratio of 0.50 is

    0.62.

    In the present case water-cement ratio is 0.44. Therefore, volume of coarse aggregate is required to be increased to decrease the fine aggregate content. As the water-cement ratio is lower by 0.06. The proportion of volume of coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio).

    Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.44

    0.632

    For pumpable concrete these values should be reduced up to 10%. Therefore, volume of coarse aggregate

    0.632 x 0.9 =0.568.

    Volume of fine aggregate content

    1 – 0.576 =0.431

    Volume of fine aggregate and coarse aggregate is 0.431 and .568 respectively

     STEP 8: MIX CALCULATIONS

    The mix calculations per unit volume of concrete shall be as follows:

    a) Volume of concrete

    1 m3

    b) Volume of cement = [Mass of cement] / [Specific Gravity of Cement] x 1/1000

    (359/3.15) X (1/1000) =0.114m3

    c) Volume of water = [Mass of water] / [Specific Gravity of water] x 1/1000

    (158/1) X (1/1000) = 0.158m3

    d) Volume of chemical admixture = [Mass of admixture] / [Specific Gravity of admixture] x 1/1000

    (7.6/1.145) X (1/1000) =0.006 m3

    e) Volume of all in aggregate = 

    [a-(b+c+d)]

    [1-(0.114+0.158+0.006)] = 0.722m3

    f) Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of Fine Aggregate x 1000

    0.722x 0.568 x 2.74 x 1000 = 1123 kg/m3

    g) Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000

    0.722x 0.431x 2.64 x 1000 = 821 kg/m3

    STEP 9: MIX PROPORTIONS

    Cement

    359 kg/m3

    Water

    158 l/m3

    Fine aggregate

    821 kg/m3

    Coarse aggregate 20mm

    1123 kg/m3

    Chemical admixture

    7.18kg/m3

    Water-cement ratio

    0.44

    Mix Proportion By weight

    1:2.28:3.12

    STEP 10: The slump shall be measured, the water content and dosage of admixture shall be adjusted for achieving the required slump on trial. The mix proportion shall be reworked for the actual water content and checked for durability requirements .
     
     
     
     
     
    PART 2:To Calculate the Concrete Mix Design for M50 grade concrete without fly ash:

     

    M50 grade concrete without Fly ash

    STEP 1: Stipulations for Concrete design mix

    Grade designation

    M50

    Type of cement

    OPC 53 Grade confirming to IS BIS 12269 - 1987

    Maximum nominal size of aggregate

    20 mm

    Minimum cement content

    320 kg/m3 (Table 5 of  IS 456:2000- Exposure condition)

    Maximum water-cement ratio

    0.45 (Table 5 of IS 456:2000 Exposure   condition)

    Workability

    100 mm (slump value for pumpable concrete)

    Exposure condition

    Severe (For Reinforced Concrete)

    Method of concrete placing

    Pumping

    Degree of supervision

    Good

    Type of aggregate

    Crushed Angular Aggregates

    Maximum cement content

    450 kg/m3

    Chemical admixture type

    Super Plasticizer

    STEP 2: TEST DATA FOR MATERIALS

    Cement used

    OPC 53 Grade conforming IS 12269-1987

    Specific gravity of cement

    3.15

    Chemical admixture

    Super Plasticizer conforming to IS 9103

    Specific gravity of coarse aggregate

    2.74

    Specific gravity of fine aggregate

    2.64

    Water absorption of coarse aggregate

    0.5%

    Water absorption of fine aggregate

    1.0%

    Free surface moisture of Coarse aggregate

    Nil

    Free surface moisture of  Coarse aggregate

    Nil

    Sieve analysis: Coarse aggregate

    Conforming to Table 2 of IS 383

    Sieve analysis: Fine aggregate

    Conforming to Grading Zone II of Table 4 of IS 383

    STEP 3: TARGET STRENGTH FOR MIX PROPORTIONING

    f’ck =fck + 1.65s

    Where

    ·        f’ck = target average compressive strength at 28 days

    ·        fck = characteristics compressive strength at 28 days, and

    ·        s = standard deviation

    From Table I of IS 10262:2009, Standard Deviation, s = 5 N/mm2.

    50 + 1.65 x 5 = 58.25 N/mm2

    Target mean strength = 58.25 N/mm2

    STEP 4: SELECTION OF WATER-CEMENT RATIO

    The maximum water-cement ratio to design M50 grade concrete can be found from Table 5 of IS 456-2000 for severe exposure.

    Maximum W/C ratio =0.45

    Based on experience adopted water cement ratio is .44

    0.44<0.45, hence ok

    Adopted W/C ratio=0.44

    STEP 5: SELECTION OF WATER CONTENT

    From Table 2 of IS 10262:2009, maximum water content for 20 mm aggregate

    186 litre (for 25 to 50 mm slump range)

    Clause 4.2 suggests increasing of 3% of water content for every extra 25mm slump from 50mm slump. So a 6% is to be added to it

    Estimated water content for 100 mm slump

    186+ (6/100)*186 = 197 litre.

    (Note: If Super plasticizer is used, the water content can be reduced up to 20% and above.)

    Based on trials with Super plasticizer water content reduction of 20% has been achieved, Hence the arrived water content

    197 X 0.8 = 158 litre

    Water required 158 litres

    EP 6: CALCULATION OF CEMENT REQUIRED

    Adopted w/c Ratio

    0.44

    Cement Content

    158/0.44 = 359 kg/m3

    From Table 5 of IS 456, Minimum cement content for ‘Severe’ exposure conditions

    320kg/m3

    359 kg/m3 > 320 kg/m3 hence ok.

    Cement required is  359 kg/m3 

    STEP 7: VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT

    From Table 3 of (IS 10262:2009) Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II) for water-cement ratio of 0.50 is

    0.62.

    In the present case water-cement ratio is 0.44. Therefore, volume of coarse aggregate is required to be increased to decrease the fine aggregate content. As the water-cement ratio is lower by 0.06. The proportion of volume of coarse aggregate is increased by 0.02 (at the rate of -/+ 0.01 for every ± 0.05 change in water-cement ratio).

    Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.44

    0.632

    For pumpable concrete these values should be reduced up to 10%. Therefore, volume of coarse aggregate

    0.632 x 0.9 =0.568.

    Volume of fine aggregate content

    1 – 0.576 =0.431

    Volume of fine aggregate and coarse aggregate is 0.431 and .568 respectively

     STEP 8: MIX CALCULATIONS

    The mix calculations per unit volume of concrete shall be as follows:

    a) Volume of concrete

    1 m3

    b) Volume of cement = [Mass of cement] / [Specific Gravity of Cement] x 1/1000

    (359/3.15) X (1/1000) =0.114m3

    c) Volume of water = [Mass of water] / [Specific Gravity of water] x 1/1000

    (158/1) X (1/1000) = 0.158m3

    d) Volume of chemical admixture = [Mass of admixture] / [Specific Gravity of admixture] x 1/1000

    (7.6/1.145) X (1/1000) =0.006 m3

    e) Volume of all in aggregate = 

    [a-(b+c+d)]

    [1-(0.114+0.158+0.006)] = 0.722m3

    f) Mass of coarse aggregate= e x Volume of Coarse Aggregate x Specific Gravity of Fine Aggregate x 1000

    0.722x 0.568 x 2.74 x 1000 = 1123 kg/m3

    g) Mass of fine aggregate= e x Volume of Fine Aggregate x Specific Gravity of Fine Aggregate x 1000

    0.722x 0.431x 2.64 x 1000 = 821 kg/m3

    STEP 9: MIX PROPORTIONS

    Cement

    359 kg/m3

    Water

    158 l/m3

    Fine aggregate

    821 kg/m3

    Coarse aggregate 20mm

    1123 kg/m3

    Chemical admixture

    7.18kg/m3

    Water-cement ratio

    0.44

    Mix Proportion By weight

    1:2.28:3.12

    STEP 10: The slump shall be measured, the water content and dosage of admixture shall be adjusted for achieving the 
    Results
     
     Mix Proportion by weight of M35 grade of concrete with fly ash is 1:2.08:2.72 and its water-cement ratio was found to be 0.4.

    Mix Proportion by weight of M50 grade of concrete without fly ash is 1:2.28:3.12 and its water-cement ratio was found to be 0.44. 
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     
     

      
     
     
     
       
     
     
     
     

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