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App.

II/1
Author:
Saroj Bhattarai, M.Sc. Structures/Highways
Senior Divisional Engineer, Department of Roads, Nepal

Disclaimer:
This document is a part of my M.Sc. thesis on Use of Superplasticizers for High
Strength Concrete, published on 1999, Tribhuwan University, Institute of
Engineering, Nepal. Readers' discretion is advised. The author bears no
responsibility to any loss or damage by use of this publication
---------------------------------------------------------------------------------------------------------------

Design procedures of concrete mixes.

I. Design of Concrete Mixes According to Indian Standard
Guidelines, IS : 10262 1982.
(Partially extracted from Design of Concrete Mixes by N.K. Raju
18
)

The basic assumption in this method is that the compressive strength of workable
concrete is by and large governed by the water/cement (w/c) ratio. The water content
and proportion of fine aggregate corresponding to a maximum size of aggregate are first
determined for reference values of workability, w/c ratio and grading of fine aggregate.
The water content and the proportion of fine aggregate are then adjusted for any
differences in workability, w/c ration and grading of fine aggregate in any particular
cases from the reference values.

The procedure is as follows:

1. The target mean strength is first determined with the relation:

f '
ck
= f
ck
+ t.s

Where,
f '
ck
= Mean design target compressive strength at 28 days
f
ck
= Required characteristic compressive strength at 28 days
s = Standard deviation (Table AII - 1)
t = A statistical value depending upon the accepted proportion of low
results and the number of tests (Table AII - 2)

App. II/2
2. The water/cement (w/c) ratio for the target mean strength is selected for the
corresponding grade of cement from suggested graph
18
. The graph can be
approximately represented by the equations given in Table AII - 3. The w/c ratio
obtained thus is checked against the limiting w/c ratio for the requirement of
durability using the Table AII- 4 and the lower value is adopted. If the concrete is
expected to be exposed to sulphate attack then further tables are required to be
referred, which are given in the relevant IS guidelines.

Table AII - 1. Suggested values of standard deviation
Grade of concrete
(f
ck
)
Standard deviation (s) for different degree of control,
N/mm
Very good Good Fair
M-10 2.0 2.3 3.3
M-15 2.5 3.5 4.5
M-20 3.6 4.6 5.6
M-25 4.3 5.3 6.3
M-30 5.0 6.0 7.0
M-35 5.3 6.3 7.3
M-40 5.6 6.6 7.6
M-45 6.0 7.0 8.0
M-50 6.4 7.4 8.4
M-55 6.7 7.7 8.7
M-60 6.8 7.8 8.8

Table AII - 2. Values of t
Percentage of results
below f
ck

50 16 10 5 2.5 1.0 0.5 0
Values of t 0 1.00 1.28 1.65 1.96 2.33 2.58


3. The air content (amount of entrapped air) is taken as 3.0, 2.0 and 1.0 percent of
volume of concrete for nominal maximum size of aggregate of 10, 20 and 40 mm.
App. II/3
4. The water content and percentage of sand in total aggregate by absolute volume are
selected from Tables AII - 5 for the appropriate reference conditions.

Table AII - 3. Approximate equations for w/c ratios
Type of
Cement
28 days strength of
cement tested according
to IS:4031-1968, N/mm
Approximate equation for w/c ratio*
Where, w/c = suggested w/c ratio
f '
ck
= Mean target strength
A 31.9 36.8 w/c = 3.74 (f '
ck
)
0.6735
B 36.8 41.7 w/c = 3.70 (f '
ck
)
- 0.6442
C 41.7 46.6 w/c = 4.915 ( f '
ck
)
- 0.705
D 46.6 51.5 w/c = 4.4857 ( f '
ck
)
- 0.6622
E 51.5 56.4 w/c = 4.7613 ( f '
ck
)
- 0.6613
F 56.4 61.3 w/c = 5.1318 ( f '
ck
)
- 0.6639
* Note: These equations are derived from the trend-line fitted in curves (given in the IS:10262-1968) by the author of
this thesis. The w/c values obtained from these equations may slightly differ from those obtained directly from the
curves.

Table AII - 4. Minimum cement content and maximum w/c ratio according to
conditions of exposure.
Exposure
#
Plain concrete Reinforced concrete
Minimum
cement
content
++
,
kg/m
Maximum w/c
ratio
Minimum
cement
content
++
,
kg/m
Maximum w/c
ratio
Mild 220 0.7 250 0.65
Moderate 250 0.6 290 0.55
Severe 310 0.5 360 0.45
# Mild completely protected against weather, or aggressive conditions, except for a brief period of exposure to
normal weather conditions during construction.
Moderate sheltered from heave rain and wind driven rain and against freezing, whilst saturated with water; buried
concrete in soil and concrete continuously under water
Severe exposed to sea water, alternate wetting and drying and to freezing while wet, subject to heavy condensation
or corrosive fumes.
++ The minimum cement content is based on 20mm aggregate. For 40mm aggregate, it should be reduced by about
10 per cent; for 12.5mm aggregate, it should be increased by about 10 per cent. When the maximum w/c ratio can be
strictly controlled the cement content in the above table may be reduced by 10 per cent.
App. II/4

Table AII - 5. Preliminary sand and water content per cubic meter of concrete for
reference conditions**
For concrete up to grade M-35 and w/c = 0.60
Maximum size of
aggregate, mm
Water content per cubic*
meter of concrete, kg
Sand as percent of total aggregate
by absolute volume, %
10 208 40
20 186 35
40 165 30
For concrete above grade M-35 and w/c = 0.35
Maximum size of
aggregate, mm
Water content per cubic*
meter of concrete, kg
Sand as percent of total aggregate
by absolute volume, %
10 200 28
20 180 25
** The reference conditions for both cases are:
Sand conforming to zone II as per IS:383-1970; Compaction Factor = 0.80 and crushed stone aggregates
* Water content corresponding to saturated surface dry aggregate.

5. The water content and percentage of sand obtained from Table AII - 5 are adjusted
to the prevailing conditions for which the mix is being designed, according to Table
AII-6.

Table AII- 6. Adjustment of values in water content and sand percentage
Change in conditions stipulated
for Table AII - 5.
Adjustments required in
Water content Percent sand in total aggregate
For sand conforming to grading
zone I, zone III or zone IV of
Table-4 or IS:383-1970
0 +1.5% for zone I
-1.5% for zone III
-3.0% for zone IV
Increase or decrease in the value
of Compacting Factor by 0.1
3% 0
Increase or decrease in free w/c
ratio by 0.05
0 1%
For rounded aggregate - 15 kg/m - 7%

App. II/5
6. The cement content is calculated from the w/c ratio. The amount of cement thus
obtained is checked against the minimum required according to Table AII - 4. For
concrete subjected to sulphate attack other tables are also referred (please see step
2).
7. With the quantities of water and cement per unit volume of concrete and percentage
of sand in the total aggregate already determined, the coarse and fine aggregate
content per unit volume of concrete are calculated from the following equations:



Where,
FA = Mass of fine aggregate in kg per cubic meter of concrete
CA = Mass of coarse aggregate in kg per cubic meter of concrete
p
fa
= Percentage of fine aggregate in total aggregate
S
fa,
S
ca
and

S
c
= Specific gravity of fine aggregate, coarse aggregate and cement
W = Mass of water in kg per cubic meter of concrete
a = Percentage of entrapped air
C = Mass of cement in kg per cubic meter of concrete

8. The amount of actual water needed is again adjusted according to the moisture
content and water absorption of both the coarse and fine aggregates.
9. If any liquid admixture is to be added then the water content should also be adjusted
to the volume of water in the admixture. Gauge water, equal to the volume of water
in the admixture, is deducted from the total water content.


(

|
.
|

\
|

=
(

|
.
|

\
|
=
c
ca
fa
c
fa
fa
S
C
W
a
S
p
CA
S
C
W
a
S
p
FA
100
1000
100
1
100
1000
100
App. II/6
II. Design of High Strength Concrete Mixes according to Erntroy
and Shaklock's method
(Partially extracted from Design of Concrete Mixes by N.K. Raju
18
)

Erntroy and Shaklock have suggested empirical graphs relating compressive strength to
an arbitrary "Reference Number" for concrete made with crushed granite coarse
aggregates and irregular gravel. The range of the degree of workability varying from
"Extremely Low" to "High" correspond to the compacting factor of 0.65 and 0.95
respectively. There are tables for relationship between the aggregate/cement ratio and
water/cement ratio according to maximum size of aggregate. The combination of coarse
and fine aggregates is made in such a way that 30 per cent of the total aggregate is
below 4.75mm. The mix design procedure is as follows:

1. The target mean strength is determined by using appropriate statistical factors. The
same method and values as in Indian Standard Guidelines can be applied for this
purpose.
2. For a given type of cement and aggregate used, the Reference Number
corresponding to the design strength at a particular age (1, 3, 7, 14, 28 and 91 days),
is interpolated from the given graphs. For the particular case of 28 days strength
with crushed stone aggregates and irregular gravel, the author of this thesis has
derived equations as follows:

RN = -0.01532 f '
ck
2
0.4473 f '
ck
+ 94.2 for irregular gravel
RN = -0.0045 f '
ck
2
1.8667 f '
ck
+ 123.65 for crushed stone

Where,
RN = Reference Number
f '
ck
= Target mean strength
Note: The equations were derived by plotting trend-line. The values obtained
directly from the graphs may slightly differ.

3. The w/c ratio to achieve the required workability is obtained from given graphs for
aggregates with maximum size of 20mm and 10mm. For the particular case of
App. II/7
maximum size of aggregate 20mm the equations in Table AII-7 can be used
according to required workability:

Table AII-7. Equations for water/cement ratio for 20mm aggregate
For extremely low workability (slump= 0mm)
w/c = 0.01138RN + 0.1989
For very low workability (slump= 0-12mm)
w/c = 0.00527RN + 0.2346
For low workability (slump= 12-25mm)
w/c = 0.0048RN + 0.228
For medium workability (slump= 25-50mm)
w/c = 0.00442RN + 0.2236
Where, w/c= water/cement ratio; RN= Reference Number
Notes: (a) The equations are derived by plotting trend-line on the graphs; the values obtained directly from the graphs
may slightly differ. (b) The values of slump are as suggested by Taylor
*
.

4. The aggregate/cement ratio to give the desired workability with the known w/c ratio
is obtained from Table AII-8.

Table AII-8. Aggregate/cement ratio for 20mm maximum aggregate size
Type of coarse aggregate

Irregular gravel Crushed stone
Workability EL VL L M EL VL L M
Water/cement
ratio by weight
0.30 3.0 - - - 3.3 - - -
0.32 3.8 2.5 - - 4.0 2.6 - -
0.34 4.5 3.0 2.5 - 4.6 3.2 2.6 -
0.36 5.2 3.5 3.0 2.5 5.2 3.6 3.1 2.3
0.38 - 4.0 3.4 2.9 - 4.1 3.5 2.6
0.40 - 4.4 3.8 3.2 - 4.5 3.8 2.9
0.42 - 4.9 4.1 3.5 - 4.9 4.2 3.1
0.44 - 5.3 4.5 3.8 - 5.3 4.5 3.3
0.46 - - 4.8 4.1 - - 4.8 3.6
0.48 - - 5.2 4.4 - - 5.1 3.8
0.50 - - 5.5 4.7 - - 5.4 4.0


*
Taylor, W.H., Concrete Technology and Practice, Angus and Robertson Ltd., Third Edition, London, 1969. Quoted
from [18]
App. II/8
5. The aggregates are to be combined such that 30 percent of the total aggregate passes
through 4.75mm sieve. This can be done either by graphical method using the
following equations:

FA = ACR (30 p
CA
) / (p
FA
p
CA
)
CA = ACR 1- {(30 p
CA
) / (p
FA
p
CA
)}
Where,
FA = Proportion of fine aggregate in total weight of 1 cubic meter of concrete
CA = Proportion of coarse aggregate in total weight of 1 cubic meter of concrete
p
FA
= Percentage of fine aggregate passing through 4.75mm sieve
p
CA
= Percentage of coarse aggregate passing through 4.75mm sieve
ACR = Aggregate / cement ratio

So the proportion of the materials by weight will be 1 : FA : CA : w/c, where
proportion of cement is taken as 1.

6. The quantity of cement is computed from the equation:


Where,
C = Quantity of cement (kg) in a cubic meter of concrete
S
c,
S
fa,
and

S
ca
= Specific gravity of cement, fine aggregate and coarse aggregate
w/c = water/cement ratio
a = percentage of entrained air
FA and CA = Proportions of fine and coarse aggregates

7. The quantities of fine and coarse aggregates and water are then computed according
to their corresponding proportions with respect to cement.
( ) ( )
100
/
1
1000
a
c w
S
CA
S
FA
S
C
ca fa c
+ +
|
.
|

\
|
+
|
.
|

\
|
+
|
.
|

\
|
=
App. II/9
8. The amount of water is adjusted for moisture content and water absorption of the
aggregates. If any liquid admixture is added then its volume of water is included in
the water content.

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