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APPENDIX – A

A.1 GENERAL

The experimental investigation starts with the basic material testing.

The basic material tests such as Sieve analysis, determination of specific
gravity and water absorption have been carried out for both fine aggregate and
coarse aggregate based on the relevant IS codes. The fine aggregate used in
the present work has been observed to fall in Grade III as per IS-383 (1970).
The coarse aggregates confirm to the IS-383 (1970). Potable water has been
used for making the concrete. OPC cement of 53 grade confirming to IS-
12269 (1987) has been used. For the experimental studies, it has been
proposed to use two concrete mixes. In the concrete mixes, the first mix is a
normal strength concrete and the next is a high strength concrete. The
concrete mix has been designed as per the IS-10262 (1982) and IS-456
(2000). A few trial mixes have been tested before arriving at the final mix.
The concrete mix ratio for the Normal Strength Concrete (NSC) is 1:2.2:3.1
with water-cement ratio (w/c) ratio of 0.55. The concrete mix ratio for the
High Strength Concrete (HSC) is 1:1.4:2.6 with w/c ratio of 0.35 along with
the CONPLAST superplasticizer of 0.7% by weight of cement.

A.2 EXPERIMENT ON BASIC MATERIAL PROPERTIES

A.2.1 Test on Fine Aggregate

A.2.1.1 Sieve Analysis

The air-dry sample of fine aggregate (FA) of 500 g has been weighed
using balance. The sieves of size 12 mm, 10 mm, 4.75 mm, 2.36 mm, 1.18
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mm, 600 μm, 300 μm have been used as per IS: 2386-Part-I (1963) and sieved
successively starting with the largest at the top. On completion of sieving, the
materials retained on each sieve have been weighed. The percentages of
aggregate retained in each sieve are as shown in Table A.1.

Table A.1 Sieve analysis for fine aggregate

Cumulative
Weight Cumulative Cumulative
percentage
IS sieve size retained weight percentage
weight
(g) retained passing
retained
4.75 mm 0 0 0 100
2.36 mm 53.175 53.175 10.635 89.365
1.18 mm 122.465 175.64 35.128 64.87
600 micron 112.235 287.875 57.575 42.425
300 micron 120.005 407.88 81.576 17.424
150 micron 87.12 495 99 1
Pan 5 - - -

sum of the cummulativ e % of aggregate retained 283 .91

Fineness modulus    2.84
100 100

It could be inferred from the above results that the fine aggregate falls under
the zone two as per IS:385 (1970).

A.2.1.2 Specific gravity & Water absorption for FA

Specific gravity of fine aggregate = (W2-W1)/ [(W4-W1) - (W3-W2)]
= 2.58
Water absorption of fine aggregate is found to be 1.25%.
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Table A.2 Specific gravity test for fine aggregates

Empty Weight of Weight of Weight of Specific

Weight of Pycnometer Pycnometer Pycnometer gravity of
S. Pycnometer and Dry + dry and water fine
(W1) kg solid sample and (W4) kg aggregate
No.
weight(W2) Water
kg (W3) kg
1 0.36 0.75 1.28 1.04 2.6
2 0.36 0.74 1.26 1.03 2.53
3 0.36 0.75 1.27 1.03 2.6

A.2.2 Test on Coarse Aggregate

A.2.2.1 Sieve Analysis

The sieve analysis for coarse aggregate (CA) has been carried out as
per IS: 2386-Part-I (1963). The percentage weight of coarse aggregate
retained in each sieve has been listed in Table A.3.

Table A.3 Sieve analysis for coarse aggregate (20 mm)

Cumulative
Weight Cumulative Cumulative
percentage
IS sieve size retained weight percentage
weight
(g) retained passing
retained
25 mm 19.255 19.255 0.963 99.037
20 mm 231.213 250.468 12.52 87.48
16 mm 740.899 991.367 49.657 49.657
12.5 mm 712.056 1703.423 85.197 14.803
8 mm 295.729 1999.152 99.95 0.05
4.75 mm 0.896 2000 100 0
Pan - - 100 0
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Table A.4 shows that the coarse aggregate conforms to the category of
CA with maximum size of 10 mm, according to the code IS:385 (1970).

Table A.4 Sieve analysis for coarse aggregate less than 12.5 mm

Cumulative
Weight Cumulative Cumulative
percentage
IS sieve size retained weight percentage
weight
(g) retained passing
retained
20mm - - - 100
12.5 mm 35.96 35.96 1.8 98.2
10 mm 475.69 511.65 25.58 74.42
4.75 mm 1456.6 1968.25 98.41 1.59
2.36 mm 23.09 1991.34 99.56 0.44
Pan 8.67 2000 100 0

A.2.2.2 Specific gravity & Water absorption of C.A

The specific gravity and water absorption of coarse aggregate are

determined from as per code IS:2386 (1963).

Specific gravity of 20mm coarse aggregate = 2.7

Specific gravity of 10mm coarse aggregate = 2.56
Water absorption of 20mm coarse aggregate is found to be 0.7%.
Water absorption of 10mm coarse aggregate is found to be 0.9%.

A.2.3 Specific gravity of cement

Specific gravity of cement is found to be 3.15

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Table A.5 Specific gravity test for cement

Weight of
Weight of
Empty container + Weight of Specific
container
Weight of dry sample container gravity
[Link] and cement
container and and water of
weight(W2)
(W1) kg kerosene (W4) kg cement
kg
(W3) kg
1 0.041 0.084 0.121 0.091 3.31
2 0.042 0.09 0.125 0.092 3.20
3 0.041 0.085 0.121 0.092 2.93

A.3 MIX DESIGN FOR NSC

M-30 Concrete mix design, As per IS 10262-2009

A-1 Stipulations for Mix proportioning

1 Grade Designation M30
2 Type of Cement OPC 53 grade
confirming to IS-
12269-1987
3 Maximum Nominal Aggregate Size 20 mm
4 Minimum Cement Content 300 kg/m3
5 Maximum Water Cement Ratio 0.5
6 Workability 50-75 mm (Slump)
7 Exposure Condition Moderate
8 Degree of Supervision Good
9 Type of Aggregate Crushed granite
Aggregate
10 Maximum Cement Content 450 kg/m3
11 Chemical Admixture Type Superplasticiser
Confirming to IS-
9103-1999
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A-2 Test Data for Materials

1 Sp. Gravity of Cement 3.15
2 Sp. Gravity of Water 1
3 Chemical Admixture SNF Based
4 Sp. Gravity of 20 mm Aggregate 2.7
5 Sp. Gravity of 10 mm Aggregate 2.56
6 Sp. Gravity of Sand 2.58
7 Water Absorption of 20 mm 0.70%
Aggregate
8 Water Absorption of 10 mm 0.90%
Aggregate
9 Water Absorption of Sand 1.25%
10 Free (Surface) Moisture of 20 mm nil
Aggregate
11 Free (Surface) Moisture of 10 mm nil
Aggregate
12 Free (Surface) Moisture of Sand nil
13 Sieve Analysis of Individual Coarse Separate Analysis Done
Aggregates
14 Sieve Analysis of Combined Coarse Separate Analysis Done
Aggregates
15 Sp. Gravity of Combined Coarse 2.65
Aggregates
16 Sieve Analysis of Fine Aggregates Separate Analysis Done

A-3 Target Strength for Mix Proportioning

1 Target Mean Strength 38.25N/mm2
2 Characteristic Strength @ 28 days 30N/mm2

A-4 Selection of Water Cement Ratio

1 Maximum Water Cement Ratio 0.5
2 Adopted Water Cement Ratio 0.5
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A-5 Selection of Water Content

1 Maximum Water content (10262- 186 Lit.
table-2)
2 Estimated Water content for 50-75 163.5 Lit.
mm Slump
3 Superplasticiser used 0.5 % by wt. of cement

A-6 Calculation of Cement Content

1 Water Cement Ratio 0.5
2 Cement Content (163.5/0.5) 327 kg/m3
Which is greater than 300
kg/m3

A-7 Proportion of Volume of Coarse Aggregate & Fine Aggregate

Content

1 Vol. of C.A. as per table 3 of 62.00%

IS:10262
2 Adopted Vol. of Coarse Aggregate 65.00%
Adopted Vol. of Fine Aggregate 35.00%
(1-0.65)

A-8 Mix Calculations

1 Volume of Concrete in m3 1
2 Volume of Cement in m3 0.1
(Mass of Cement) / (Sp. Gravity of
Cement)x1000
3 Volume of Water in m3 0.164
(Mass of Water) / (Sp. Gravity of
Water)x1000
4 Volume of Admixture @ 0.5% in m3 0
(Mass of Admixture)/(Sp. Gravity of
Admixture)x1000
5 Volume of All in Aggregate in m3 0.736
Sr. no. 1 – (Sr. no. 2+3+4)
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6 Volume of Coarse Aggregate in m3 0.478

Sr. no. 5 x 0.65
7 Volume of Fine Aggregate in m3 0.258
Sr. no. 5 x 0.35

A-9 Mix Proportions for One Cum of Concrete (SSD Condition)

1 Mass of Cement in kg/m3 327

2 Mass of Water in kg/m3 163.5
3 Mass of Fine Aggregate in kg/m3 665
3
4 Mass of Coarse Aggregate in kg/m 1268
Mass of 20 mm in kg/m3 761
Mass of 10 mm in kg/m3 507
5 Mass of Admixture in kg/m3 0
6 Water Cement Ratio 0.5

A.4 MIX DESIGN FOR HSC

Design for M 60 grade concrete as per ACI 211.4R-08

DESIGN STIPULATION
Characteristic Compressive strength = 60MPa
Maximum size of aggregate used = 20 mm
Specific gravity of cement = 3.15
Specific gravity of fine aggregate (F.A) = 2.58
Specific gravity of Coarse aggregate (C.A) = 2.65
Dry Rodded Bulk Density of fine aggregate = 1700kg/m3
Dry Rodded Bulk Density of coarse aggregate = 1619kg/m3

Step-1 Calculation for weight of Coarse Aggregate:

From ACI 211.4R Table 6.3 Fractional volume of oven dry Rodded C.A for
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20 mm size aggregate is 0.72 m3

Weight of C.A = 0.72*1619 = 1165.7kg/m3

Step-2 Calculation for Quantity of Water:

From ACI 211.4R Table 6.4
Assuming Slump as 25 to 50 mm and for C.A of size 20 mm, the mixing
water = 169kg/m3
Void content of FA for this mixing water = 35%
Void content of FA (V)
V = {1-(Dry Rodded unit wt / specific gravity of FA*1000)}*100
= [1-(1700/2.58*1000)]*100
= 34.1%
Adjustment in mixing water = (V-35)* 4.55
= (34.1 – 35)*4.75
= -4.275 kg/m3
Adjustment in mixing water = 169 kg/m3-4.275kg/m3
= 164.73 kg/m3
From ACI 211.4R Table 6.5 w/c ratio is 0.31 for M60.

Based on experience adopted a water cement ratio of 0.30.

0.3< 0.31, hence ok.

As superplsticiser is used, the water content can be reduced up to 20 percent

and above.

Based on trials with SP water content reduction of 18 percent has been

achieved.

Hence the water content arrived = 164.7 x 0.82 =135 liters

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Taking w / c ratio = 0.30

Weight of cement = 135 / 0.3 = 450 kg/m3

Step-3
Calculation for weight of Fine Aggregate:
Cement = 450 / 3.15*1000= 0.143
Water = 135 / 1*1000= 0.135
CA = 1165.7/ 2.65*1000= 0.439
Entrapped Air = 2 / 100= 0.020
Total = 0.737m3
Volume of Fine Aggregate= 1-0.737
Weight of Fine Aggregate= 0.263*2.58*1000= 678.54 kg/m3

Step-4
Super plasticizer:
For 0.9% = (0.9 / 100)*450 = 4.05kg/m3
Requirement of materials per Cubic meter
Cement = 450kg/m3
Fine Aggregate = 678.54kg/m3
Coarse Aggregate = 1165.7kg/m3
Water = 135kg/ m3
Super plasticizers = 4.05 kg/ m3

So the final ratio becomes(kg/m3):

Cement : Fine agg. : Courseagg. : Water
1 : 1.51 :2.59 :0.30