CHAPTER 5: PILOT STUDY

5.1 The Casting Procedure of Concrete

Casting of concrete plays most important role for achievement of good

workability, strength and batter durability. Such that, the batching, mixing and casting
operations are carefully done.

5.1.1 Mixing

The materials are weighted first on the weighting machine as per the mix
design by IS specification. For the material to be mixed, the drum type of the
mixture machine is used as shown in Figure below.

Figure 6.1. Mixing of Concrete

5.1.2 Moulding and Vibrating

The cube mould having the size (150 x 150 x 150) mm, the cylinder mould
having the size (150 x 300) mm and the beam mould with size (150 x 150 x 700) mm
are used in the casting of this project. Compaction is given to the cube and cylinder
moulds using a standard tamping bar at every 50 mm layer with 35 strokes at each
layer of concrete. And vibration is given to the beam moulds using machine vibrator
as shown below.
 Fig. 5.3 Beam, cube and cylinder moulds

5.1.3 De-moulding and Curing

After 24 hours of the casting, the specimens are de-moulded and are
transferred to curing tank where in they are allowed to cure for 7, & 28 days.
5.2 Mix design for M 25 Grade of concrete as per IS 10262:2009

Trial mix - 1

Data :-
Grade design = M25
Type of cement = OPC 53
Maximum nominal size of aggregate = 20 mm
Minimum cement content = 320 kg/m3
Maximum cement content = 450 Kg/ m3
Maximum water-cement ratio = 0.55
Workability in terms of Slump = 50 mm
Exposure condition = moderate
Degree of supervision = Good
Type of aggregate = Crushed angular aggregate
Chemical Admixture = Nil

Test Data:-

Specific gravity of cement = 3.15

a) Coarse aggregate
Specific gravity = 2.68

Water absorption = 0.6%

Free (surface) moisture = Nil

b) Fine aggregate

Specific gravity
= 2.65
Water absorption = 1%

Free (surface) moisture = Nil

A) Targeted Mean strength for the Mixture,

Fck = f + KS
Here f = 25
K = 1.65
Standard deviation (S) = 4 (Reference: IS: 10262: 2009, Table-1)
Fck = f + KS
Fck = 25 + (1.65 x 4) = 31.6 N/mm2
Fck = 31.6 N/mm2
B) Selection of water cement ratio,
From table 5 of IS: 456: 2000 max water-cement ratio = 0.55 (Moderate exposure)
Based on the experience it is adopt water cement ratio as 0.47< 0.55 ...................O.K
C) Selection of water content,
Maximum water content = 186 litres (for 25mm 50 mm slump range of 20 mm
aggregate) (Reference: IS: 10262: 2009, Table-2)
D) Calculation of cement content,
Cement content =186 / 0.47 = 407.617 kg/m3 > 300 kg/m3...................................O.K
Because Minimum cement content for moderate exposure condition from table 5 of
IS 456:2000 is 300 kg/m3.
E) Proportion of volume of coarse aggregate and fine aggregate content,
Volume of coarse aggregate corresponding to 20 mm size aggregate and fine
aggregate for water cement ration of 0.50 = 0.60
For the zone II the volume of coarse aggregate = 0.62
(Reference: IS: 10262: 2009, Table-3)
So, the volume of fine aggregate = 0.38

F) Mix Calculation :-
3
1) Volume of concrete = 1 m
2) Volume of cement = (mass of cement / S.G. of cement) x (1/1000)
= (407.617/3.15) x (1/10000)
= 0.1294 m3
3) Volume of water = (mass of water / S.G. of water) x (1/1000)
= (191.58/1) x (1/1000)
= 0.191 m3
4) Volume of all in aggregate = 1- (Volume of cement+ Volume of water)
= 1- (0.1294+0.191)
 = 0.6796 m3
5) Volume of coarse aggregate = 0.6796 x 0.62 x S.G. of coarse aggregate x 1000
= 0.6796 x 0.62 x 2.68 x 1000
= 1128.3 kg/m3
6) Volume of fine aggregate = 0.6796 x 0.38 x S.G. of fine aggregate x 1000
= 0.696 x 0.36 x 2.65 x 1000
= 683.771 kg/m3
G) Mix:-
Cement = 407.617 kg/m3
Water = 191.58 kg/m3
Fine aggregate = 683.771 kg/m3
Coarse aggregate = 1128.3 kg/m3
Water cement ratio = 0.47

Mix proportion for the Mix Design is

Mix Proportions

Mix Ratio W/C Ratio Water Cement Sand Aggregates

1: 1.67: 2.76 0.47 191.58 407.6 683.77 1128.3

Trial mix 2
Data :-
Grade design = M25
Type of cement = OPC 53
Maximum nominal size of aggregate = 20 mm
Minimum cement content = 300 kg/m3
Maximum water-cement ratio = 0.50
Workability in terms of Slump = 75 mm
Exposure condition = moderate
Degree of supervision = Good
Type of aggregate = Crushed angular aggregate
Maximum cement content = 450 Kg/ m3
Chemical Admixture = Nil

Test Data:-
Specific gravity of cement = 3.15
a) Coarse aggregate
Specific gravity = 2.68
Water absorption = 0.60%
Free (surface) moisture =Nil
b) Fine aggregate
Specific gravity = 2.65
Water absorption = 1%
Free (surface) moisture = Nil
A) Targeted Mean strength for the Mixture,
Fck = f + KS
Here f = 25
K = 1.65
Standard deviation (S) = 4 (Reference: IS: 10262: 2009, Table-1)
Fck = f + KS
Fck = 25 + (1.65 x 4) = 26.6 N/mm2
Fck = 31.6 N/mm2

B) Selection of water cement ratio,

From table 5 of IS: 456: 2000 max water-cement ratio = 0.50 (Mild exposure)
Based on the experience it is adopt water cement ratio as 0.50 = 0.50 ...................O.K

C) Selection of water content,

Maximum water content = 186 litres (for 25mm 50 mm slump range of 20 mm
aggregate) (Reference: IS: 10262: 2009, Table-2)
Estimated water content = 186 + (0.03x186)
= 191.6 litres

D) Calculation of cement content,

Cement content =191.6 / 0.5 = 383.2 kg/m3 > 300 kg/m3...................................O.K
Because Minimum cement content for moderate exposure condition from table 5 of
IS 456:2000 is 300 kg/m3.

E) Proportion of volume of coarse aggregate and fine aggregate content,

Volume of coarse aggregate corresponding to 20 mm size aggregate and fine
aggregate for water cement ration of 0.50 = 0.60
For the zone II the volume of coarse aggregate = 0.62
 (Reference: IS: 10262: 2009, Table-3)

So, the volume of fine aggregate = 0.38

F) Mix Calculation :-

3
1) Volume of concrete = 1 m
2) Volume of cement = (mass of cement / S.G. of cement) x (1/1000)
= (383.2/3.15) x (1/1000)
= 0.121 m3
3) Volume of water = (mass of water / S.G. of water) x (1/1000)
= (191.6/1) x (1/1000)
= 0.191 m3
4) Volume of all in aggregate = 1- (Volume of cement+ Volume of water)
= 1- (0.121+0.191)
= 0.688 m3
5) Volume of coarse aggregate = 0.688 x 0.64 x S.G. of coarse aggregate x 1000
= 0.688 x 0.62 x 2.68 x 1000
= 1143.18 kg/m3
6) Volume of fine aggregate = 0.688 x 0.38 x S.G. of fine aggregate x 1000
= 0.688 x 0.38 x 2.65 x 1000
= 691.6 kg/m3

G) Mix:-
Cement = 383.2 kg/m3
Water = 191.6 kg/m3
Fine aggregate = 691.6.35 kg/m3
Coarse aggregate = 1143.18 kg/m3
Water cement ratio = 0.50
Mix proportion for the Mix Design is

Mix Proportions
 Mix Ratio W/C Ratio Water Cement Sand Aggregates

1: 1.80 : 2.98 0.5 191.6 383.2 691.6 1143.18

4.2 Results of pilot study:

During pilot study, the cubes (0.15 x 0.15 x 0.15 m3) were casted by using the mix
ratios (1: 1.67: 2.76) and (1: 1.80: 2.98) as per is specification and compressive
strength at 7 days was carried out..
1) 3 cubes with normal M 25 grade concrete design.
2) 3 cubes with 10% replacement of metakaoin with cement.
3) 3 cubes with 10% metakaoin or 5% rice husk ash replacements with cement
4) 3 cubes with 10% metakaoin or 15 % rice husk ash replacements with cement
Table 4.1 Compressive strength for different trial mix at 7-days

Trial Mix - 1(1: 1.67: 2.76) Trial Mix 2 (1: 1.80: 2.98)
Compressive Strength Compressive Strength
Load Load
(MPa) (MPa)

410 18.22 430 19.11

390 17.33 510 22.66

350 15.55 460 20.44

Average Compressive Strength= 17.03 Average Compressive Strength= 20.73

MPa MPa
From the above result , I conclude that the trial mix-2 gives batter
compressive strength compare to trial mix-1.
Table 4.2 Compressive strength for replacement of M.K + RHA at 7-days
10% Metakaolin + 5% 10% Metakaolin + 15% Rice
Rice husk ash husk ash
Compressive Compressive
Load Load
Strength (MPa) Strength (MPa)
460 20.44
500 22.22
 490 21.77
530 23.55

475 21.11
480 21.33

Average Compressive Average Compressive Strength=

Strength= 22.36 MPa 21.10 MPa
From the above result , we conclude that the optimum dossage of silica fume with the
replacement of cement is between 0 % to 10%